Yanmar 3JH4ME Service manual
Yanmar 3JH4ME is a powerful and reliable marine diesel engine designed for a variety of applications. It features a compact and lightweight design, making it ideal for use in small boats and yachts. The 3JH4ME is also highly fuel-efficient, making it an economical choice for boat owners. With its advanced technology and durable construction, the Yanmar 3JH4ME is sure to provide years of trouble-free operation.
Advertisement
Advertisement
M9961-03E090
Service Manual
3JH4(B)(C)(M)E
M9961-03E090
Manual Name
Engine Model:
Number of revision
Date of revision
3JH4(B)(C)(M)E
Reason for correction
New edition January 2004
Publication No.
History of Revision
Service Manual for Marine Diesel Engine
Outline of correction
M9961-03E090
Correction item
No (page)
Corrected by
Printed in Japan
M9961-03E090
FOREWORD
This service manual has been complied for engineers engaged in sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual, while items, which should already be common knowledge, are omitted.
One characteristic of a marine diesel engine is that its performance in a vessel is governed by the applicability of the vessel's hull construction and its steering system.
Engine installation, fitting out and propeller selection have a substantial effect on the performance of the engine and the vessel. Moreover, when the engine runs unevenly or when trouble occurs, it is essential to check a wide range of operating conditions - such as installation to the full and suitability of the ship's piping and propeller - and not just the engine itself. To get maximum performance from this engine, you should completely understand its functions, construction and capabilities, as well as proper use and servicing.
Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering guidance.
Model 3JH4E has been used for the illustrations in this service manual, but they apply to other models in the JH4 series engines.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands, after handling.
The contents of this service manual may not be copied or reproduced without permission.
FOR SAFTY
1. SAFETY LABELS
• Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consideration for safety is required in addition to the matters marked . Especially for safety precautions in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable leader.
• Safety marks used in this manual and their meanings are as follows:
DANGER
-indicates an imminent hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
-indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION
-indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• NOTICE
- indicates that if not observed, the product performance or quality may not be guaranteed.
2. Safety Precautions
(1) SERVICE AREA
• Sufficient Ventilation
Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas.
• Safe / Adequate Work Area
The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip" or "trip and fall" type accidents.
• Clean, orderly arranged place
No dust, mud, oil or parts should be left on the floor surface.
[Failure to Observe]
An unexpected accident may be caused.
• Bright, Safely Illuminated Area
The work area should be well lit or illuminated in a safe manner. For work in enclosed or dark areas, a "drop cord" should be utilized. The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances.
• Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be close at hand (or easily accessible) in case of an emergency.
(2) WORK - WEAR (GARMENTS)
Well fitting !!
• Safe Work Clothing
Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness', clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery.
(3) TOOLS
• Appropriate Lifting / Holding
When lifting an engine, use only a lifting device (crane, jack, etc.) with sufficient lifting capacity. Do not overload the device. Use only a chain, cable, or lifting strap as an attaching device. Do not use rope, serious injury may result.
To hold or support an engine, secure the engine to a support stand, test bed or test cart designed to carry the weight of the engine. Do not overload this device, serious injury may result
Never run an engine without being properly secured to an engine support stand, test bed or test cart, serious injury may result.
• Appropriate Tools
Always use tools that are designed for the task at hand. Incorrect usage of tools may result in damage to the engine and or serious personal injury.
(4) GENUINE PARTS and MATERIALS
• Genuine Parts
Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.
(5) FASTENER TORQUE
• Torqueing Fasteners
Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury.
(6) Electrical
• Short Circuits
Always disconnect the (-) Negative battery cable before working on the electrical system. An accidental "short circuit" may cause damage, fire and or personal injury. Remember to connect the (-) Negative battery cable (back onto the battery) LAST
• Charging Batteries
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is extremely explosive. Keep sparks, open flame and any other form of ignition away. Explosion may occur causing severe personal injury.
• Battery Electrolyte
Batteries contain sulfuric acid. Do NOT allow it to come in contact with clothing, skin and or eyes, severe burns will result.
(7) WASTE MANAGEMENT
Observe the following instructions with regard to hazardous waste disposal. Negligence of these will have a serious impact on environmental pollution concerns.
1) Waste fluids such as lube oil, fuel and coolant shall be carefully put into separate sealed containers and disposed of properly.
2) Do NOT dispose of waste materials irresponsibly by dumping them into the sewer, overland or into natural waterways.
3) Waste materials such as oil, fuel, coolant, solvents, filter elements and batteries, must be disposed of properly according to local ordinances.
Consult the local authorities or reclamation facility.
(8) FURTHER PRECAUTIONS
• Fueling / Refueling
Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result.
• Hot Surfaces.
Do NOT touch the engine (or any of its components) during running or shortly after shutting it down. Scalding / serious burns may result. Allow the engine to cool down before attempting to approach the unit.
• Rotating Parts
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or tools may become entangled causing damage to the engine and or severe personal injury.
• Preventing burns from scalding
1) Never open the radiator filler cap shortly after shutting the engine down.
Steam and hot water will spurt out and seriously burn you. Allow the engine to cool down before attempt to open the filler cap.
2) Securely tighten the filler cap after checking the radiator.
Steam can spurt out during engine running, if tightening loose.
• Safety Label Check
Pay attention to the product safety label.
A safety label (caution plate) is affixed on the product for calling special attention to safety.
If it is missing or illegible, always affix a new one.
3. Precautions for Service Work
(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
(2) Preparation for Service Work
Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
• Preceding service date
• Period/operation hours after preceding service
• Problems and actions in preceding service
• Replacement parts expected to be required for service
• Recording form/check sheet required for service
(3) Preparation before Disassembly
• Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts, and parts expected to be required for replacement.
• When disassembling complicated portions, put match-marks and other marks at places not adversely affecting the function for easy reassembly.
(4) Precautions in Disassembly
• Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface defect, etc.
• Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again.
• Parts to be used again shall be washed and cleaned sufficiently.
• Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump.
(5) Precautions for Inspection and Measurement
Inspect and measure parts to be used again as required to determine whether they are reusable or not.
(6) Precautions for Reassembly
• Reassemble correct parts in correct order according to the specified standards (tightening torques, and adjustment standards). Apply oil important bolts and nuts before tightening when specified.
• Always use genuine parts for replacement.
• Always use new oil seals, O-rings, packing and cotter pins.
• Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact portions, and apply grease to oil seal lips.
(7) Precautions for Adjustment and Check
Use measuring instruments for adjustment to the specified service standards.
CONTENTS
2.4.1 Oil pressure switch ................................................................... 38
2.4.2 Thermo switch ....................................................................... 38
5.1.2 Cleaning of oil holes .................................................................. 93
5.2.2 Valve seat correction procedure........................................................ 98
5.2.3 Intake/exhaust valves, valve guides .................................................... 99
5.2.5 Assembling the cylinder head......................................................... 102
5.2.6 Measuring top clearance ............................................................. 102
5.2.7 Intake and exhaust rocker arms ....................................................... 103
5.3 Piston and Piston Pins ..........................................................104
5.3.2 Piston pin .......................................................................... 105
5.3.3 Piston rings ........................................................................ 105
5.4 Connecting Rod ................................................................108
5.4.1 Inspecting the connection rod......................................................... 108
5.4.3 Piston pin bushing .................................................................. 111
5.4.4 Assembling piston and connecting rod ................................................. 111
5.5.2 Main bearing ....................................................................... 115
5.6.1 Camshaft .......................................................................... 116
5.7.2 Gear timing marks .................................................................. 119
6.1.1 Fuel system diagram ................................................................ 122
6.2 Fuel Feed Pump ................................................................133
6.2.1 Construction of fuel feed pump........................................................ 133
6.3 Fuel Filter .....................................................................136
7.1.1 Breather system (A reductor to intake air system of blowby gas)........................... 138
8.2.1 Lube oil pump construction ........................................................... 142
8.3.1 Lube oil filter construction ............................................................ 144
9.2.3 Seawater pump Inspection ........................................................... 149
9.4.1 Heat exchanger construction ......................................................... 153
9.4.2 Specifications of heat exchanger ...................................................... 153
9.5.1 Pressure cap construction............................................................ 154
9.5.5 Function of the coolant recovery tank .................................................. 156
9.6.2 Thermostat construction ............................................................. 157
12.1 Electrical System ..............................................................171
12.3.2 Characteristics .................................................................... 175
12.4.3 Wiring diagram .................................................................... 180
12.5.3 Wiring diagram .................................................................... 184
12.6.1 B-type instrument panel (optional).................................................... 185
12.6.2 C-type instrument panel ............................................................ 185
12.7.2 Sender unit for lube oil pressure gauge ............................................... 187
12.7.4 Sender unit for the cooling water temperature gauge ................................... 188
12.9 Electric Engine Stopping Device (Optional) .......................................190
14. TIGHTENING TORQUE FOR BOLTS AND NUTS ................................................... 197
1. GENERAL
1. GENERAL
1.1 Exterior Views
(1) 3JH4E
Operating Side
Intake silencer Intake manifold Dipstick
Fuel filter
Fuel injection pump
Oil filter cap
Fuel feed pump
Lubricating oil filter
Shift lever
Marine gear
Non-Operating Side
Oil cooler
Engine name plate (on the rocker arm cover)
Fresh water filler cap
Coolant tank / Heat exchanger
Alternator
Exhaust manifold
Mixing elbow
Starter motor
Sea water pump
<Note> This illustration shows the 3JH4E with Yanmar marine gear (Model:KM35P).
1
1. GENERAL
1.2 Specifications
(1) 3JH3E, 3JH3BE, 3JH3CE, 3JH4ME
Official engine model name
Company internal model name
Marine gear model
Use
Type
Combustion system unit
-
-
-
-
-
Air charging
Number of cylinders -
-
Bore x stroke mm(inch)
Displacement L
Continuous power
Output at crankshaft /
Engine speed kW(HP)/ min -1
3JH4E 3JH4BE
KM35P KM35A
3JH4E
3
3JH4CE
SD40
Pleasure use
Vertical water cooled 4 cycle diesel engine
Direct injection
Naturally aspirated
88 x 90 (3.46 x 3.54)
26.7(36.3) / 2907 (at Fuel temp. 25°C)*
3JH4ME
Bobtail
Output at crankshaft /
Engine speed kW(HP)/ min -1
Fuel stop power
Output at propeller shaft /
Engine speed kW(HP)/ min
Installation -
-1
Fuel injection timing
Fuel injection opening pressure deg b.T.D.C.
MPa
(kgf/cm 2 )
Main power take off
Crankshaft
Direction of rotation
Propeller shaft
(Ahead)
Cooling system
-
-
-
29.4(40.0) / 3000 (at Fuel temp. 25°C)*
28.7(39.0) / 3000 (at Fuel temp. 40°C)* *
28.0(38.1) / 3000 (at Fuel temp. 25°C)*
27.4(37.3) / 3000 (at Fuel temp. 40°C) **
At flywheel side
Counter-clockwise viewed from stern
Clockwise viewed from stern -
-
FID 12±1 (FIC-Air 13±1)
21.6±0.5 (2.12±0.05)
-
-
L(quart)
Fresh water cooling with heat exchanger
Complete enclosed forced lubrication
Engine:4.5 (4.8), Coolant recovery tank : 0.8 (0.8)
Lubrication system
Cooling water capacity (fresh)
Lubricating oil capacity
(engine)
Rake angle
Total (Note 4)
Oil pan only
Effective (Note 5) deg.
L(quart) at rake angle 8 deg at rake angle 0 deg -
-
-
5.0±0.3 (5.3±0.3) 5.5±0.3 (5.8±0.3) 5.5±0.3 (5.8±0.3) 5.5±0.3 (5.8±0.3)
4.5±0.3 (4.8±0.3) 5.0±0.3 (5.3±0.3) 5.0±0.3 (5.3±0.3) 5.0±0.3 (5.3±0.3)
1.1 (1.2) 1.2 (1.3) 1.2 (1.3) 1.2 (1.3)
Starting system
Type -
Starting motor V-kW
AC generator
Overall length
V-A
Engine
Dimension
Overall width
Overall height
Flywheel major dimension
Engine dry mass
(include marine gear) mm(inch) mm(inch) kg
777 (30.6)
539 (21.2)
623 (24.5)
185
Electric
DC 12V-1.4 kW
12V-60A (12V-80A optional)
776 (30.6) 700 (27.6)
539 (21.2)
623 (24.5)
186
539 (21.2)
623 (24.5)
Ø300 x 66 (11.8 x 2.6)
212
(engine:173)
700 (27.6)
539 (21.2)
623 (24.5)
173
2
1. GENERAL
(Note)
1. Rating condition : ISO 3046-1, 8665
2. 1HP (metric horse power) ≒ 0.7355 kW
3. Fuel condition : Density at 15°C = 0.842
* Fuel temperature 25°C at the inlet of the fuel injection pump. (ISO 3046-1)
** Fuel temperature 40°C at the inlet of the fuel injection pump. (ISO 8665)
4. The "Total" oil quantity includes: oil in oil pan and oil in channels, coolers and filter.
5. The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
(2) Sales condition, Marine gear
Reduction ratio
(Marine gear model)
2.61 (KM35P)
2.64 (KM35A)
2.36 (KM35P)
2.33 (KM35A)
No. of blades
3 (A/R=0.52)
4 (A/R=0.69)
3 (A/R=0.52)
4 (A/R=0.69)
Outer diameter of propeller
(inch)
Moment of propeller inertiaI
GD
2
N•m 2 (kgf•m 2 ) propeller materials
18
17
18
17
2.94 (0.30)
2.55 (0.26)
Bronze
Engine application
3JH4(B)E
3
4- 10.5
PC 78
6 7.5
4
MIXING ELBOW
U-MIXING ELBOW
174 MOUNTING BLOCKS ID#150
7
DETAIL OF COUPLING
SCALE 1:3
(274)
194.1
538.6
517.6
243.6
(OPTIONAL)
169.3
174
206
12 X 30
MOUNTING BLOCKS ID#100
412
143
190
DIRECTION OF ROTATION
3-M10 X 1.5
DEPTH 14 / 20
DETAIL OF PULLEY
SCALE 1:3
ROTATION
167
93.2
330
120.4
480
6
(72.5)
724.3
777.3
47
NOTE
1. The original height of mounting blocks is shown in this drawing. Engine weight will compress
blocks by 4mm (approx).
2. The figures marked with show the dimensions with u-mixing elbow, or optional coupling.
6 7.5
MIXING ELBOW
U-MIXING ELBOW
MOUNTING BLOCKS ID#150
7
DETAIL OF COUPLING
SCALE 1:3
(274)
194.1
538.6
517.6
243.6
(OPTIONA
L)
168
174
206
12 X 30
MOUNTING BLOCKS ID#100
412
143
190
DIRECTION OF ROTATION
3-M10 X 1.5
DEPTH 14 / 20
DETAIL OF PULLEY
SCALE 1:3
ROTATION
167
93.2
330
120.4
480
ASTERN
AHEAD
5.955
(72.5)
723
776
47
NOTE
1. The original height of mounting blocks is shown in this drawing. Engine weight will compress
blocks by 4mm (approx).
2. The figures marked with show the dimensions with u-mixing elbow, or optional coupling.
(274)
194.1
538.6
517.6
243.6
MOUNTING BLOCKS ID#200
7
DIRECTION OF ROTATION
3-M10 X 1.5
DEPTH 14 / 20
(OPTIONA
185
MOUNTING BLOCKS ID#200
538
L)
174
206
143
12 X 30
DETAIL OF PULLEY
SCALE 1:3
420
480
167
Available propeller dia. 181 inch max.
(185)
(112.5)
538
973
372
143 47
NOTE
1. The original height of mounting blocks is shown in this drawing. Engine weight will compress
blocks by 4mm (approx).
2. The figures marked with show the dimensions with u-mixing elbow, or optional coupling.
1.General
1.4 Piping Diagrams
(1) 3JH4(B) E
Note: The following piping diagram is for the 3JH4E model.
Marks of piping
Screw joint (Union)
Flange joint
Eye joint
Insertion joint
Drill hole
Cooling fresh water piping
Cooling seawater piping
Lubricating oil piping
Fuel oil piping
7.8 x t4.5 rubber hose
7.8 x t4.5 rubber hose
Check valve
7.8 x t4.5 rubber hose
Fuel oil filter (cartridge type)
Pressure control valve
Lubricating oil pump
Fresh water temperature switch
D
27 x t4 rubber hose
Hot water connection inlet (R3/8)
Cooling water pump (fresh water)
28.6 x t2 copper pipe
Thermostat
Hot water connection outlet (R3/8)
28 x t4 rubber hose
28 x t4 rubber hose
Cooling water pump (seawater)
P
P
P
7.8 x t4.5 rubber hose
5 x t4.5
rubber hose
C
7.8 x t4.5 rubber hose
Fuel feed pump
Fuel injection pump
4.76 x t0.7 steel pipe
9 x t3.5 rubber hose
Lubricating oil filter (cartridge type)
Lubricating oil cooler
5 x t4.5 rubber hose
Fuel high pressure pipe
Fuel injection nozzle
9 x t3.5 rubber hose
Oil pressure switch
P
T
From cylinder head
To cam shaft
B
Mixing elbow
Notes
1. Dimension of steel pipe : outer dia. x thickness.
Dimension of rubber pipe : inner dia. x thickness.
2. Fuel rubber pipes (marked ) satisfy EN/ISO7840.
25.4 x t4.3 rubber hose
A
Fresh water cooler
Lubricating oil inlet filter
Main bearing
25 x t1.8 copper pipe
25.4 x t4.3 rubber hose
25.4 x t4.3 rubber hose
7
26
Detail of part A
45
Detail of part B
9
8
Detail of part C
8
8.5
Detail of part D
1.General
(2) 3JH4CE (with sail drive SD40)
Marks of piping
Screw joint (Union)
Flange joint
Eye joint
Insertion joint
Drill hole
Cooling fresh water piping
Cooling seawater piping
Lubricating oil piping
Fuel oil piping
7.8 x t4.5 rubber hose
7.8 x t4.5 rubber hose
Check valve
7.8 x t4.5 rubber hose
Fuel oil filter (cartridge type)
Pressure control valve
Lubricating oil pump
Fresh water temperature switch
D
27 x t4 rubber hose
Hot water connection inlet (R3/8)
Cooling water pump (fresh water)
28.6 x t2 copper pipe
Thermostat
Hot water connection outlet (R3/8)
28 x t4 rubber hose
28 x t4 rubber hose
Cooling water pump (seawater)
P
P
P
7.8 x t4.5 rubber hose
5 x t4.5
rubber hose
C
7.8 x t4.5 rubber hose
Fuel feed pump
Fuel injection pump
4.76 x t0.7 steel pipe
9 x t3.5 rubber hose
Lubricating oil filter (cartridge type)
Lubricating oil cooler
5 x t4.5 rubber hose
Fuel high pressure pipe
Fuel injection nozzle
9 x t3.5 rubber hose
Oil pressure switch
P
T
From cylinder head To cam shaft
B
Mixing elbow
Notes
1. Dimension of steel pipe : outer dia. x thickness.
Dimension of rubber pipe : inner dia. x thickness.
2. Fuel rubber pipes (marked ) satisfy EN/ISO7840.
25.4 x t4.3 rubber hose
Fresh water cooler
Lubricating oil inlet filter
Main bearing
25 x t1.8 copper pipe
25.4 x t4.3 rubber hose
25.4 x t4.3 rubber hose
25.4 x t4.3 rubber hose
45
Detail of part B
9
8
Detail of part C
8
8.5
Detail of part D
8
1.general
1.5 Exhaust Gas Emission Regulation
The EPA and ARB (,California Air Resources Board)
Off-road Compression Ignition engines regulations
1.5.1 Engine identification (3JH4E)
With the regulations on exhaust gas emission worldwide, it has become necessary to identify engines in a manner to determine which regulations they comply with, hence
(1) Emission control label
(EPA and ARB label)
(Note) Emission Control is accomplished through Engine Modification (EM-Design)
• The tamper resistance device is installed with EPA/ARB certified 3JH4E series engines to prevent illegal change of fuel injection volume and high idling speed.
(Fuel injection volume : cap type, High idling speed : cap type)
• Engine family name as assigned by EPN/ARB identifying engine family group
4YDXM1.64D3N and this identifies
YYDXM1.64D3N and this identifies
4 YDX M 1.64 D 3 N
Method of air aspiration
Number of cylinders
Combustion chamber design
Displacement (liter)
Marine engine
Yanmar
*2004 Model Year
Y : 2000
1 : 2001
2 : 2002
3 : 2003
4*: 2004
5 : 2005
(2) Label location:
Emission control label
9
1.General
1.5.2 Exhaust Gas Regulations
This engine conforms to the EPA exhaust gas regulations (19kW and under 37kW).
Engine Power
19 <= kW < 37
(25 <= hp < 50)
Tier
Tier 1
Tier 2
Model Year
1999
2004
NOx
-
-
HC
-
-
NMHC + NOx
9.5 (7.1)
7.5 (5.6)
CO PM
5.5 (4.1) 0.80 (0.60)
5.5 (4.1) 0.60 (0.45)
Note
1. The transit smoke (ACC/LUG/PEAK) is not applicable.
2. The EPA recommended fuel is used.
3. The ARB standard is the same as the EPA's.
1.5.3 Guarantee Conditions for Emission Standard
In addition to making sure that these conditions are met, check for any deterioration that may occur before the required periodic maintenance times.
(1) Requirement on engine installation condition
(a) Air intake negative pressure kPa (mmAq)
Permissible
¹ 3.9 (400)
(b) Exhaust gas back pressure kPa (mmAq)
Permissible
¹ 14.7 (1500)
(2) Fuel oil and lubricating oil
(a) Fuel: The diesel fuel oil [BS 2869 A1 or A2 (Cetane No.45 min.)]
(b) Lube oil : API grade, class CD
(3) Do not remove the caps restricting injection quantity and engine speed.
(4) Perform maintenance without fail.
Note : Inspections to be carried out by the user and by the maker are divided and set down in the "List of
Periodic Inspection" on the operation manual and should be checked carefully.
EPA allows to apply Maintenance schedule for Emission related parts as follows.
Power Rating
19 ¹ kW < 37
Parts Fuel nozzle cleaning
Every 1500 hours
Maintenance period
Adjustment, cleaning, repairs for fuel nozzle, fuel pump, and electronic control unit etc.
Every 3000 hours
10
1.general
(5) Quality guarantee period for exhaust emission related parts
For exhaust emission related parts, follow the inspections outlined in the "List of Periodic Inspections", on the operation manual, and use the table below to carry out inspections based on operation hours or time in years. Whichever comes first is the guarantee period.
19 ¹ kW < 37 3000 hours or 5 years
The specific emissions-related parts are
(a) Fuel injection nozzle
(b) Fuel injection pump
11
2. Inspection and Adjustment
2. Inspection and Adjustment
2.1 Periodic Maintenance Schedule
The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here.
System Item
{ : User-maintenance Å : Parts replacement z : Shop-inspection
Before starting
*
2 Initial
50hrs. or one month
*
2 Every
50hrs. or one month
* 2 Every
250 hrs. or one year
* 2 Every
1000 hrs. or
4 years
Whole Visual inspection of engine outside
Check the fuel level, and refill
Drain the fuel tank
Fuel system
Drain the fuel/water separator
Replace the fuel filter
Check the injection timing
Check the injection spray condition
{
{
{
{
{
Å z z * 1
Lubricating system
Check the lube oil level
Crankcase
Marine gear
Replace the lube oil
Crankcase
Marine gear
{
{
Å
Å
Å
Å
Replace the engine lube oil filter.
Å Å
Seawater outlet
{
(During operation)
Cooling system
Check cooling water level
Check the impeller of the cooling water pump (seawater pump)
{
{ Å
Replace the fresh water
Every year
When long life coolant of the specified type is used, the replacement period of two years can be obtained.
z
Air intake and exhaust system
Electrical system
Clean & check the water passages
Clean the element of the air intake silencer
Clean the exhaust/water mixing elbow
Diaphragm assembly inspection
Check the alarm lamps & devices
Check the electrolyte level in the battery
Adjust the tension of the alternator driving belt
Check the wiring connectors
{
{
-
{
{
{
{ z
Å
12
2. Inspection and Adjustment
System Item
{ : User-maintenance Å : Parts replacement z : Shop-inspection
Before starting
*2 Initial
50hrs. or one month
*2 Every
50hrs. or one month
*2 Every
250 hrs. or one year
*2 Every
1000 hrs. or
4 years
Check the leakage of water, lube oil and fuel.
Cylinder head, etc.
Remote control system, etc.
Retighten all major nuts and bolts
Adjust intake/exhaust valve clearance
Check/adjust the remote control operation
Adjust the propeller shaft alignment
{
(After starting)
{ z
{ z z z z z
*1 For EPA requirements see also 1.5 in chapter 1.
*2 Whichever comes first
13
2. Inspection and Adjustment
2.2 Periodic Inspection and Maintenance Procedure
2.2.1 Check before starting
Be sure to check the following points before starting an engine every day.
No.
Inspection Item
(1) Visual inspection of engine outside
(2) Check the fuel level, and refill
(3) Check the lube oil level (Crankcase/Marine gear)
(4) Seawater outlet
(5) Check cooling water level
(6) Check the alarm lamps & devices
(7) Check the leakage of water, lube oil and fuel.
(8) Check/adjust the remote control operation
(1) Visual inspection of engine outside
If any problem is found, do not use before the engine repairs have been completed.
• Oil leak from the lubrication system
• Fuel leak from the fuel system
• Cooling water leak from the cooling water system
• Damaged parts
• Loosened or lost bolts
• Fuel, coolant tank rubber hoses, V belt cracked, loosened clamp
(2) Check the fuel level, and refill
Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary.
(3) Check the lube oil level (Crankcase/Marine gear)
1) Checking engine lube oil level a) Check the lube oil level of a engine with a dipstick. Insert the dipstick fully and check the oil level. The oil shall not be contaminated heavily and have appropriate viscosity. No cooling water or diesel fuel shall be mixed.
Standard
The level shall be between the upper and lower limit lines on the dipstick.
Rocker arm cover
Filter port
Dipstick
Upper limit
Lower limit
Model
Unit: liter(quart)
Engine oil capacity at rake angle 8 degree
Full : 5.0 ± 0.3 (5.3 ± 0.3) 3JH4E with KM35P
3JH4E with KM35A
3JH4E with SD40
Full : 5.5 ± 0.3 (5.8 ± 0.3) b) If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through the filler port.
[NOTICE]
The engine oil should not be overfilled to exceed the upper limit line. If engine oil is overfilled, the engine may intake the engine oil in the combustion chamber during the operation, and white smoke, oil hummer or urgent rotation may occur, because the blowby gas is reduced in the suction air flow.
14
2. Inspection and Adjustment
2) Checking marine gear lube oil level a) Check the lube oil level of the marine gear with a dipstick.
KM35P
KM35A
Unit: liter(pint)
Marine gear oil capacity
Full : 0.50 (1.0)
Full : 0.65 (1.4) b) When the level is low, remove a filler port cap at the top of the housing, and fill it with marine gearclutch- lube oil to the upper limit on the dipstick.
c) Tighten the filler port cap securely by hand.
Oil filler cap
Dipstick
(4) Seawater outlet
Check whether seawater comes out just after the engine has started.
If seawater doesn't come out, shut down the engine immediately.
Check the leakage of seawater in the seawater pass and the damage of the seawater pump impeller.
(5) Check cooling water level
Daily inspection of cooling water should be done only by coolant recovery tank.
• Never open the filler cap while the engine is still hot. Steam and hot water will spurt out and seriously burn you. Wait until the engine is cooled down after the engine stopped, wrap the filler cap with a rag piece and turn the cap slowly to gently release the pressure inside the flesh water tank.
• Securely tighten the filler cap after checking the flesh water tank. If the cap is tightened loosely, steam can spurt out during operation.
1) Checking cooling water volume
Check the cooling water level in the coolant recovery tank. If the water level is close to the
LOW mark, open the coolant recovery tank cap and replenish the coolant recovery tank with clean soft water to the FULL mark.
Standard
The water level of the coolant recovery tank shall be between the upper and lower limit lines.
To fresh water cooler
Rubber hose
Coolant recovery tank
FULL
LOW
Cap
2) Replenishing engine with water
If the cooling water levelin the coolant recovery tank is lower than the LOW mark, open the filler cap and check the cooling water level in the coolant tank. Replenish the engine with the cooling water, if the level is low.
• Check the cooling water level when the engine is cool.
Checking when the engine is hot is dangerous. And the water volume is expanded due to the temperature.
• Daily cooling water level check and replenishing shall be done only at the coolant recovery tank.
Usually do not open the filler cap to check or replenish.
Standard
Cooling water volume
Engine
4.5
(Unit: liter)
Coolant recovery tank
0.8
15
2. Inspection and Adjustment
IMPORTANT:
If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the water level of the coolant recovery tank during operation is not abnormal.
The increased water in the coolant recovery tank returns to the coolant tank when the engine is cooled down.
If the water level is normal in the coolant recovery tank but low in the coolant tank, check loosened clamping of the rubber hose between the coolant tank and coolant recovery tank or tear in the hose.
(6) Check the alarm lamps & devices
Before and after starting the engine, check to see that the alarm functions normally. Failure of alarm cannot warn the lack of the engine oil or the cooling water. Make it a rule to check the alarm operation before and after starting engine every day.
When the sensor detects a problem during operation, the lamp comes on and the buzzer goes off.
Alarm lamps are located on the panel, buzzer is located on the back of panel.
Under normal conditions, the monitors are off. When there is a problem, the monitors light up.
Battery low charge alarm
Coolant high temperature alarm
Lubricating oil low pressure alarm
Water in sail drive seal alarm
Water in fuel filter alarm
(C type only)
When the alternator output is too low, the lamp will come on.
When charge begins, the lamp will turn off.
(The alarm buzzer will not sound, when the lamp comes on.)
When the temperature reaches the maximum (95° C [203F] or higher), the lamp will light.
Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure.
Check the load and the fresh water cooling system for any abnormalities.
When the lubricating oil pressure falls below normal, the oil pressure sensor will register this and the lamp will come on and alarm will sound.
Continuing operation with insufficient oil pressure will result in damage and seizure.
Check the oil level.
When seawater is detected between the seals of sail drive, the lamp will come on and the alarm will sound.
This function is not available on this engine.
Seawater insufficient flow alarm
(C type only)
This function is not available on this engine.
Normal action of alarm devices
Alarm devices act as shown below. Check that the alarm lamps and buzzer are working normally, when the key is turned on.
Key switch
Engine
Alarm buzzer
Alarm lamps
Battery low charge alarm
Coolant high temperature alarm
Lubricating oil low pressure alarm
Water in sail drive seal alarm
OFF → ON
Before start
Goes on
Light
Off
Light
Off
START → ON
Running
Stop
Off
Off
Off
Off
16
2. Inspection and Adjustment
(7) Check the leakage of water, lube oil and fuel.
Brfore and after starting the engine, check the leakage of cooling water and seawater from cooling water system. Also check the leakage of lube oil and fuel.
(8) Check/adjust the remote control operation
Make sure that the accelerator of a boat can be operated smoothly before starting the engine. If it feels heavy to manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever.
2.2.2 inspection after initial 50 hours or one month operation
Be sure to check the following points after initial 50 hours or one month operation, whichever comes first.
No.
Inspection Item
(1) Drain the fuel tank
(2) Replace the engine lube oil and the lube oil filter
(3) Replace the marine gear lube oil
(4) Adjust the tension of the alternator driving belt
(5) Adjust the intake/exhaust valve clearance
(6) Check/adjust the remote control operation
(7) Adjust the propeller shaft alignment
(1) Drain the fuel tank
1) Put a pan under the drain cock to catch the fuel.
2) Open the drain cock and drain off any water or dirt collected.
3) When the water and dirt are drained off and the fuel comes out, close the drain cock.
(2) Replace the engine lube oil and the lube oil filter.
During the operation of an engine, the oil is quickly contaminated due to the initial wear of internal parts.
The lubricating oil must therefore be replaced early. It is easiest and most effective to drain the engine lubricating oil after operation while the engine is still warm.
Replace the lubricating oil filter at the same time.
Fuel pipe
To engine
Sediment
Drain cock
Beware of oil splashes if extracting the Lubricating oil while it is hot
1) Remove the lubricating oil dipstick and also the oil filler cap at the top of the rocker arm cover. Attach the oil drain pump to the dipstick guide and drain off the lube oil.
[Notice]
For easier draining, remove the oil filler cap (yellow) at the top of the rocker arm cover.
When lubricating oil is absorbed without removing a oil filler cap, negative pressure grows big in the crankcase and it may cause the rubber of the diaphragm cracked.
2) Turn the lubricating oil filter counter-clockwise using a filter wrench to remove it.
17
Dipstick guide
Lube oil filter
Filter wrench
2. Inspection and Adjustment
3) Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench.
Tightening torque: 20-24N•m (177-212 lb-in)
Applicable oil filter Part No.
119305-35150
4) Fill with new lubricating oil.
5) Perform a trial run of the engine and check the oil leakage.
6) Approximately 10 minutes after stopping the engine, check the oil level by using the oil dipstick. Add oil if the level is too low.
[Notice]
When checking the oil level right after the engine running, the oil level in the dipstick guide decreases drastically, and the accurate oil measurement can't be performed because the pressure in the cylinder block decreases with the function of the diaphragm in the rocker arm cover. Therefore, measure the lube oil level after removing the oil filler cap or about 10 minutes later after stopping the engine.
(3) Replace the marine gear lube oil.
During initial operation, the oil is quickly contaminated due to the initial wear of internal parts. The lubricating oil must therefore be replaced early.
1) Remove the cap from the filler port and attach the oil drain pump. Drain off the oil.
2) Fill with new lubricating oil.
3) Perform a trial run of the engine and check the oil leakage.
(4) Adjust the tension of the alternator drive belt
When there is not enough tension in the V-belt, it will slip and the cooling water pump will fail to supply cooling water. Engine over-heating and the seizure will occur.
When there is too much tension in the V-belt, the belt will become damaged more quickly and the bearing of the cooling water pump may be damaged.
Check and adjust the V-belt tension (deflection) in the following manner.
[Notice]
Be especially careful not to splash engine oil on the
V-belt, because it will cause slipping, stretching and aging of the belt.
1) Remove the belt cover. Check the tension of the Vbelt by pressing down on the middle of the belt with your finger [approx. 98N(10kgf)].
The specified deflection should be as follows.
For used V-belt
For new V-belt
8-10mm (0.315-0.393 inches)
6-8mm (0.236-0.315 inches)
• "New V-belt" refers to a V-belt which has been used less than 5 minutes on a running engine.
• "Used V-belt" refers to a V-belt which has been used on a running engine for 5 minutes or more.
18
2) If necessary, adjust the V-belt tension (deflection).
To adjust the V-belt tension, loosen the set bolt for the belt adjuster and move the alternator to tighten the V-belt.
3) Visually check the V-belt for cracks, oiliness or wear. If any, replace the V-belt with new one.
[Notice]
When the V-belt will be replaced with new one, loosen the set bolt and move the alternator and also loosen the V-pulley set bolts for the cooling water pump. Remove the V-belt.
After replacing with a new V-belt and adjusting the tension, run the engine for 5 minutes and readjust the deflection to the value in the table above.
Set bolt
2. Inspection and Adjustment
Belt adjuster
Alternator
Adjust the V-belt tension inserting a bar
Adjuster
Alternator
(Tension adjustment)
(5) Adjusting the intake/exhaust valve clearance
Make measurement and adjustment while the engine is cold.
1) Valve clearance measurement a) Remove the rocker arm cover above cylinder head.
b) Set the No.1 cylinder in the compression TDC
Turn the crankshaft to bring the piston of the
No.1 cylinder to its compression top dead center while watching the rocker arm motion, the timing mark of the flywheel housing and the top mark of the flywheel.
(Position where both the intake and exhaust valves are closed.)
Injection timing marks
No.1 cylinder
T.D.C.
Flywheel
Flywheel housing
(Notes)
• The crankshaft shall be turned clockwise as seen from the gear case side.
• The No.1 cylinder position is on the opposite side of the gear case.
Hole
• Since there is a clearance between the rocker arm and valve at the compression top dead center, the position of TDC can be checked by hand Also see that the top mark on the flywheel aligns with the mark on the flywheel housing. If there is no valve clearance, disassemble and inspect around the valve seat, since the valve seat may be worn abnormally.
19
2. Inspection and Adjustment c) Valve clearance measurement
Insert a thickness gage between the rocker arm and valve cap, and record the measured valve clearance.
(Use it as the data for estimating the wear state.)
Valve clearance
Rocker arm Adjusting screw
Lock nut d) Adjusting other cylinders
Turn the crankshaft 240 ° and make adjustment for the No.3 cylinder. Then adjust the No.2
cylinder in this order.
The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the
(Valve clearance) cylinder where the piston is the nearest to the top dead center after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 ° e ach time.
The adjustment method of reducing the flywheel turning numbers (for reference):
Set NO.1 cylinder to the compression T.D.C. and adjust the clearance of the z mark of the below table. Next, turn the flywheel once (the suction/ exhaust valve of NO.1 cylinder is in the position of the overlap T.D.C. at this time), and adjust the clearance of the { mark.
Ignition order of 3 cylinder engines: 1 → 3 → 2
Cylinder No.
Valve
No.1 compression
T.D.C
No.1 overlap T.D.C
1 2 3
Suction Exhaust Suction Exhaust Suction Exhaust z z z
{ { z The first time
The second time
2) Valve clearance inspection and adjustment a) Loosen adjusting bolts
Loosen the lock nut and adjust the screw. And check the valve for any inclination of valve cap, entrance of dirt or wear.
Valve cap
(Normal) (Abnormal) b) Measure valve clearance
Insert a 0.2 mm thickness gage between the rocker arm and valve cap, and adjust the valve clearance. Tighten the adjusting bolt.
Standard valve clearance (mm)
0.15-0.25
c) Apply oil to the contact surface between adjusting screw and push rod.
d) Adjusting other cylinders
Turn the crankshaft 240 ° then and make adjustment for the No.3 cylinder. Then adjust the
No.2 cylinder in this order.
The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the
(Valve clearance adjustment) cylinder where the piston is the nearest to the top dead center after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 ° each time.
20
2. Inspection and Adjustment
(6) Check and adjust the remote control operation
The various control levers on the engine side are connected to the remote control lever by the remote control cable. The cable will become stretched and the attachments loose after long hours of use causing deviation. It is dangerous to control operation under these conditions, and the remote control cable must be checked and adjusted periodically.
1) Adjusting the Throttle Remote Control Cable
Check to see that the control lever on the engine side moves to the high speed stop position and low speed stop position when the remote control lever is moved to H (high speed) and L (low speed) respectively.
When there is deviation, loosen the bracket for the remote control cable on the engine side and adjust.
Adjust the high speed stop position first and then adjust the low speed idling by the adjustment bolt on the remote control lever.
Remote control cable
High speed limiting bolt
Control lever
Cable joint
Fuel injection pump
Low speed limiting bolt
Never adjust the high speed limiting bolt. This will void warranty.
2) Adjusting the Clutch Remote Control Cable
Check that the shift lever moves to the correct position, when the remote control handle is put in
NEUTRAL, FORWARD and REVERSE position.
Use the NEUTRAL position as the standard for adjustment. When there is deviation, loosen the clamp for the remote control cable and adjust the shift lever position
Marine gear
Remote control cable
Clamp
Shift lever
(7) Adjust the propeller shaft alignment
The flexible engine mounts is compressed a little in the initial engine operation and it may cause the centering misalignment between the engine & the propeller shaft.
1) Check unusual noise and vibration of the engine / boat hull, while increasing the engine speed gradually and lowering it.
2) If there is unusual noise and/or vibration, adjust the propeller shaft alignment. (Refer to 6.4.5
"Centering the Engine" in the installation manual for pleasure boat use.)
21
2. Inspection and Adjustment
2.2.3 Inspection every 50 hours or monthly
Be sure to check the following points every 50 hours or monthly, whichever comes first.
No.
Inspection Item
(1) Drain the fuel/water separator.
(2) Check the electrolyte level in the battery
(1) Drain the fuel/water separator.
1) Close the fuel cock of the fuel tank.
2) Loosen the drain plug and drain off any water and dirt collected inside.
[NOTE:]
If no drain drips when the drain plug is opened, loosen the air bleeding plug on the top of the fuel/ water separator by turning counter-clockwise 2-3 times.
(This may occur in case of the fuel/water separator position is higher than the fuel oil level in the fuel tank).
3) After draining, be sure to tighten the air bleeding plug.
4) Be sure to bleed air in the fuel system.
Air bleeding bolt
Drain plug
(Fuel/water separator)
22
Fuel System Air bleeding Procedures
1) Check the fuel level in the fuel tank. Replenish if
Insufficient.
2) Loosen the air bleeding bolt at the top of the fuel/ water separator by turning it 2 or 3 turns. When fuel, which does not contain air bubbles, comes out of the bolt hole, tighten the air bleeding bolt.
3) Loosen the air bleeding bolt of the fuel filter by turning it 2 or 3 turns.
4) Feed fuel with the fuel feed pump by moving the lever on the left side of the feed pump up and down.
5) Allow the fuel containing air bubbles to flow out from the air bleeding bolt hole. When the fuel no longer contains bubbles, tighten the air bleeding bolt. This completes the air bleeding of the fuel system.
6) After the engine start-up, the automatic airbleeding device works to purge the air in the fuel system. No manual air-venting is required for normal engine operation.
Fuel nozzle
2. Inspection and Adjustment
Air bleeding bolt
To fuel tank
Fuel filter
Fuel injection pump
Fuel feed pump
(2) Check the electrolyte level in the battery
Fire due to electric short-circuit
• Make sure to turn off the battery switch or disconnect the negative cable
(-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires.
• Always disconnect the (-) Negative battery cable first before disconnecting the battery cables from battery. An accidental "Short circuit" may cause damage, fire and or personel injury.
And remember to connect the (-) Negative battery cable (back onto the battery) LAST.
Proper ventilation of the battery area
Keep the area around the battery well ventilated, paying attention to keep away any fire source. During operation or charging, hydrogen gas is generated from the battery and can be easily ignited.
Do not come in contact with battery electrolyte
Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid. The battery electrolyte is dilute sulfuric acid and causes burns. Wash it off immediately with a large amount of fresh water if you get any on you.
23
2. Inspection and Adjustment
Battery structure
Terminal
Cap
Cover
Cathode plate
Separator
Glass mat
Battery case
Anode plate
(1) Electrolyte level
• Check the level of fluid in the battery.
When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode.
• Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified times.
• If the engine cranking speed is so slow that the engine does not start up, recharge the battery.
• If the engine still will not start after charging, replace the battery.
• Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at -15 ° C or less. And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature.
(2) Battery charge
Use a battery tester or hydrometer and check the battery condition. If the battery is discharged, recharge it.
(a) Measurement with a battery tester
When checking the battery with the batter tester, connect the red clip of the tester to the battery positive
(+) terminal and black clip to the battery negative (-) terminal by pinching them securely, and judge the battery charge level from the indicator position.
Green zone: Normal
Yellow zone: Slightly discharged
Red zone: Defective or much discharged
Upper limit
OK
GREASE
UPPER LEVEL
LOWER LEVEL
Too low
Electrolyte level
Lower limit
Excessive
Battery tester
( Battery charge measurement with battery tester
)
24
2. Inspection and Adjustment
(b) Measurement with hydrometer
When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20 ° C as the standard.
Since the specific gravity increases or decreases by
0.0007 when the temperature varies by 1 ° C, correct the value according to the equation below.
S 20 = St + 0.007 ( t - 20 )
Electrolyte temperature at measurement
Specific gravity at measurement
Converted specific gravity at 20 C
Float
( Battery charge measurement ) with a hydrometer
Specific gravity and remaining battery charge
Specific gravity
(20°C)
1.28
1.26
1.24
1.23
Discharged quantity of electricity
0
10
20
25
(%)
Remaining charge
100
90
80
75
(%)
Rubber bulb
Glass tube
Float
(Hydrometer structure)
(3) Terminals
Clean if corroded or soiled.
(4) Mounting bracket
Repair or replace it if corroded.
Retighten if loosened.
(5) Battery appearance
Replace the battery if cracked or deformed.
Clean with fresh water if contaminated.
(How to read hydrometer)
25
2. Inspection and Adjustment
2.2.4 Inspection every 250 hours or one year
Be sure to check the following points every 250 hours or one year operation, whichever comes first.
No.
(1) Drain the fuel tank
Inspection Item
(2) Replace the fuel filter
(3) Replace the engine lube oil and the lube oil filter.
(4) Replace the marine gear lube oil and the lube oil filter.
(5) Check the impeller of the cooling water pump(seawater pump)
(6) Replace the fresh water
(7) Clean the exhaust/water mixing elbow
(8) Adjust the tension of the alternator driving belt
(9) Check the wiring connectors
(1) Drain the fuel tank
Refer to 2.2.2(1) for the procedure.
(2) Replace the fuel filter
Replace the fuel filter with new one at the specified interval, before it is clogged with dust to advesely affect the fuel flow. Also, replace the fuel filter after the engine has fully been cooled.
1) Close the fuel cock of the fuel tank.
2) Remove the fuel filter using a filter wrench(customer procured). When removing the fuel filter, hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping.
3) Clean the filter mounting surface and slightly apply fuel oil to the gasket of the new fuel filter.
4) Install the new fuel filter manually turning until it comes into contact with the mounting surface, and tighten it further to one turn using a filter wrench.
Tightening torque: 20-24N•m
Fuel filter
Applicable fuel filter Part No.
129470-55702
5) Bleed the fuel system. Refer to 2.2.3.(1).
IMPORTANT:
Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorten engine life.
(3) Replace the engine lube oil and the lube oil filter.
Refer to 2.2.2(2) for the procedure.
(4) Replace the marine gear lube oil and the lube oil filter.
Refer to 2.2.2(3) for the procedure.
26
2. Inspection and Adjustment
(5) Check the impeller of the cooling water pump (seawater pump).
1) Remove the seawater pump cover and take out the O-ring, impeller and wear plate,
2) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace if necessary.
Depending on the use, the inside parts of a seawater pump may deteriorate and the discharge performance may drop. At the specified interval or when the discharge volume of seawater is reduced, inspect the seawater pump in accordance with the following procedures.
Cover
O-ring
Impeller
Wear plate
3) Loosen the seawater pump cover set bolts and remove the cover.
4) Illuminate the inside of the seawater pump with a flashlight and inspect.
Pump body
(Sea water pump)
5) If no damage is found, reassemble the cover
6) If any of the following problems are found, take out the O-ring, impeller and wear plate. If necessary, replace with new one and reassemble the cover.
• Impeller blades are cracked or nicked. Edges or surfaces of the blades are marred or scratched.
Note: The impeller must be replaced periodically (every 1000 hrs or four years whichever comes first).
• Wear plate is damaged.
7) If a large amount of water leaks continuously from the water drain pipe beneath the seawater pump during engine operation, check the oil seal inside the seawater pump.
[Notice]
The seawater pump turns in the counterclockwise direction, but the impeller must be installed by turning in the clockwise direction. If the impeller has been removed for any reason and must be reassembled, be very careful not to make a mistake and turn it in the wrong direction. Additionally, if the engine is being turned manually, be careful to turn it in the correct direction. Incorrect turning will twist the impeller blades and damage it
Direction of impeller
Impeller rotating direction
Impeller
(6) Replace the fresh water.
Be sure to replace the fresh water every year. When the long life coolant is used of the specified type, the replacement period of two years can be obtained.
Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) to the cooling water in order to prevent rust built up and freezing.
Cooling performance drops when cooling water is contaminated with rust and scale.
Even if antifreeze or antirust is added, the cooling water must be replaced periodically because the properties of the agent will degenerate.
1) Open the three cooling water cocks for fresh water and extract the fresh water.
Note:
One drain cock is behind the belt cover. Remove the belt cover and open the cock.
27
2. Inspection and Adjustment
2) Close the three water cocks for fresh water.
Model
3JH4E
Fresh water line
3
Seawater line
1
Fresh water pump Coolant tank
Drain cock for fresh water
Drain cock for seawater
Drain cock for fresh water
Seawater pump
3) Remove the filler cap of the fresh water cooler by turning the cap counterclockwise 1/3 of a turn.
Flywheel housing
Filler cap
Drain cock for fresh water
Notches
Tabs
Freshwater cooler
4) Pour cooling water slowly into the coolant tank so that air bubbles do not develop. Pour until the water overflows from the filler port.
If the filler cap is loose, hot steam and water will spout out which may cause burns.
5) After supplying cooling water, replace the filler cap and tighten it firmly. To reassemble the cap, align the tabs on the bottom of the cap with the notches on the filler port and turn clockwise 1/3 of a turn.
6) Remove the coolant recovery tank cap and fill with coolant mix to the lower limit. Replace the cap to the coolant recovery tank.
Coolant recovery tank capacity: 0.8 L(1.7 pints)
28
2. Inspection and Adjustment
7) Check the rubber hose connecting the coolant recovery tank to the fresh water cooler. Be sure the hose is securely connected and there is no looseness or damage.
When the hose is not watertight, an excessive amount of cooling water will be used.
To fresh water cooler
Rubber hose
Coolant recovery tank
FULL
LOW
Cap
(7) Clean the exhaust/water mixing elbow.
There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow.
1) Clean dirt and scale out of the air pass and seawater pass of the mixing elbow.
2) Repair the crack or damage of the mixing elbow by welding, or replace if necessary.
3) Inspect the gasket and replace if necessary.
Seawater
L-type mixing elbow
Gasket
Exhaust manifold
(8) Adjust the tension of the alternator driving belt.
Refer to 2.2.2(4).
29
2. Inspection and Adjustment
(9) Check the wiring connectors.
Check whether each connection part doesn't have looseness.
Alternator
Neutral safety switch
(Fitting to marine gear)
Battery switch
Battery
Starting motor
Optional
Starter B terminal
Starter S terminal
Earth bolt
Magnetic relay Safety relay
Flywheel housing
Optional
C.W. temp. sensor
C.W. temp. switch
Optional
Air heater
(Intake manifold)
Relay
Optional
Stop solenoid
Extension wire harness
S T O P
10
20
0
30
40
50
G L O W
O F F
O N
S T A R T
Sail drive
2 place expression (optional)
30
2. Inspection and Adjustment
2.2.5 Inspection every 1,000 hours or four years
Be sure to check the following points every 1,000 hours or four years operation, whichever comes first.
No.
Inspection Item
(1) Check the injection timing
(2) Check the injection spray condition of a fuel nozzle
(3) Check the impeller of the cooling water pump(seawater pump)
(4) Clean & check the water passages
(5) Diaphragm assembly inspection
(6) Adjust the tension of the alternator driving belt
(7) Retighten all major nuts and bolts
(8) Adjust intake/exhaust valve clearance
(9) Check/adjust the remote control operation
(10) Adjust the propeller shaft alignment
(1) Check the injection timing
The fuel injection timing is adjusted so that engine performance may become the best condition. As for the inspection and adjustment of the fuel pump, it is based on the service manual of the CLH pump. The fuel injection timing is adjusted by the following procedure.
Injection timing marks
Flywheel housing
No.1 cylinder
1) Complete air bleeding from the fuel line and set the engine ready for starting.
2) See that the timing marks on fuel pump mounting flange and gear case are aligned.
T.D.C.
Flywheel
Hole
3) Set the speed control lever at the operating position.
4) Disconnect the injection pipe on the fuel pump side for the No.1 cylinder. (Do not remove the delivery holder.)
5) Check the fuel discharge from the delivery holder while turning the crankshaft clockwise as seen from the radiator, and stop turning it at the same time when the fuel comes out. Wipe out the fuel of the delivery holder exit. Next, turn the crankshaft in the opposite direction (counterclockwise), and return it to about 20 degrees before top dead center.
6) Check again the fuel discharge from the delivery holder while turning the crankshaft clockwise, and stop turning it at the same time when the fuel comes out.
7) Read the timing scale on the flywheel from the hole on the flywheel housing. It is standard fuel injection timing if the timing mark position meets the fuel injection timing of the below table.
Injection timing FID (FIC-Air) bTDC
12 ±1 (13±1)
8) Repeat the step 5) to 7) a few times.
(Note)
Injection timing check for one cylinder is generally sufficient. If it is to be checked for all cylinders, check each cylinder in the ignition order of 1-3-2-1,
The cylinder to be checked is not limited to the No.1 cylinder and any cylinder may be checked.
9) If the injection timing is out of the standard value, loosen the fuel pump mounting nut and incline the fuel injection pump toward or away from the engine for adjustment. Incline toward the engine to delay the timing, and away from the engine to advance it.
31
2. Inspection and Adjustment
(2) Check the injection spray condition of a fuel nozzle
Wear protective glasses when testing injection from the fuel injection nozzle. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.
1) Injection pressure measurement
Standard
MPa(kgf/cm 2 )
21.1-22.1
(215-225)
Nozzle tester
[Notice]
As for the opening pressure of the brand-new fuel nozzle, about 0.5MPa (5kgf/cm) declines by the engine operation for about 5 hours because of the initial wear-out of a spring etc. Therefore, adjust
0.5MPa (5kgf/cm) higher than the standard value of the above table when adjusting a new fuel nozzle of a spare part.
Remove carbon deposit at the nozzle hole thoroughly before measurement.
(
Injection nozzle
Injection pressure measurement ) with nozzle tester a) Connect the fuel injection valve to the high pressure pipe of the nozzle tester.
b) Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle starts.
c) If the measured injection pressure is lower than the standard level, replace the pressure adjusting shim with a thicker one.
Thickness of pressure adjusting shims mm
Injection pressure adjustment
0.13, 0.15, 0.18, 0.4, 0.5, 0.8
The injection pressure is increased by approx. l.9 MPa (l9 kgf / cm
when the adjusting shim thickness is increased by 0.l mm.
2 ),
32
2. Inspection and Adjustment
[Informative: Fuel injection valve structure]
F.O. return pipe joint
Nozzle holder
Pressure adjusting shim
Nozzle spring
Nozzle spring seat
Pin
Valve stop spacer
Nozzle valve
Nozzle body
Nozzle
Nozzle case nut
Tightening torque:
39.2 to 44.1 N m (4 to 4.5 kgf m)
2) Spray pattern inspection
After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness.
a) Seat oil tightness check
• After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a little before the valve opening pressure of
1.96 MPa (20kgf/cm 2 ), and check to see that oil does not drip from the tip end of the nozzle.
• If extreme oil leak from the overflow joint exists during injection by the nozzle tester, check after retightening. If much oil is leaking, replace the nozzle assembly.
Normal
(Uniform spray pattern from each nozzle)
33
2. Inspection and Adjustment b) Spray and injection states
• Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection.
• If normal injection as shown below cannot be obtained, replace the fuel injection valve.
• No extreme difference in angle( Θ )
• No extreme injection angle difference( α )
• Finely atomized spray
• Excellent spray departure
Abnormal
Extreme difference in angle ( )
Extremely different injection angle ( )
Non-atomized spray
Stagnant spray
3) Nozzle valve sliding test
Wash the nozzle valve in clean fuel oil. Place the nozzle body vertically and insert the nozzle into the body to about 1/3 of its length. The valve is normal if it smoothly falls by its own weight into the body.
In case of a new nozzle, remove the seal peel, and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust-preventive oil before using the nozzle. Note that a new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer air.
4) Nozzle punch mark
(Nozzle valve sliding check by gravity)
A 159 P 18 5 VAD1
Injection angle
Nozzle insertion angle
CodeA: angled
No code: no angle
Design code
Number of hole
(5 holes)
Diameter of hole
( 0.18)
Size: sizeP
sizeS
YANMAR
Punch mark
(3) Check the impeller of the cooling water pump(seawater pump)
The impeller must be replaced with new one periodically (every 1000 hrs or four years whichever comes first).
Refer to 2.2.4 (5) for the procedure.
34
2. Inspection and Adjustment
(4) Clean & check the water passages
When it is used for a long time, cleaning of the cooling water passages is periodically necessary, because trash, scales, rust, and so on collect in the cooling water passages and the cooling performance declines.
(a) Cleaning and inspection of cooling water rubber hoses.
1) Remove the cooling water rubber hoses for the fresh water line and the seawater line.
2) Check the dust and trash inside the hoses. If necessary, clean it.
3) Check the crack and the deterioration of the rubber hoses. If necessary, replace with new ones.
4) Replace the used hose clips with new ones, if necessary.
(b) Heat exchanger inspection
1) Cooler core inspection a) Inspect the inside of the tubes for rust or scale buildup from seawater, and clean with a wire brush if necessary.
NOTE: Disassemble and wash when the cooling water temperature reaches 85 ° C.
b) Check the joints at both ends of the tubes for looseness or damage, and repair if loose, Replace if damaged or corroded c) Check tubes and replace if leaking.
d) Clean any scale or rust off the outside of the tubes.
2) Heat exchanger body water Leakage test a) Check heat exchanger body and side cover for dirt and corrosion. Replace, if excessively corroded, or cracked.
b) Inspect seawater and fresh water inlets and outlets, retighten any joints as necessary and clean the insides of the pipes.
c) Check the exhaust gas intake flange and line, and replace if corroded or cracked.
3) Heat exchanger body water leakage test a) Compressed air/water tank test
Fit rubber covers on the fresh water and seawater inlets and outlets. Place the heat exchanger in a water tank, geed in compressed air from the overflow pipe and check for any
(water) leakage, (air bubbles).
Pressure gauge
Air hose
Filler cap
Rubber cap
Tast tank
Rubber cap Heat exchanger b) Use of the tester
Fit the fresh and seawater inlets and outlets with rubber covers and fill the fresh water tank with fresh water. Fit a pressure cap tester in place of the pressure cap, operate the pump for one minute and set the pressure at 0.15MPa
(1.5kgf/cm 2 , 21.33lb/in.
pressure will not fall.
2 ). If there are any leaks the pressure will not rise. If there are no leaks the
Rubber cap
Pressure tester
Pressure gauge
Rubber cap
35
2. Inspection and Adjustment
4) Pressure cap inspection
Do not open the pressure cap while the engine is running or right after stopping because high temperature steam will be blown out. Remove the cap only after the water cools down.
a) Remove scale and rust and check the seat and seat valve, etc. for scratches or wear. Check the spring for corrosion or settling. Replace if necessary.
[NOTE]
Clean the pressure cap with fresh water as it will not close completely if it is dirty.
b) Fit the adopter on the tester to the pressure cap.
Pump until the pressure gauge is within the specified pressure range 0.074-0.103MPa (0.75-
1.05kgf/cm 2 ) and note the gauge reading. The cap is normal if the pressure holds for six seconds. If the pressure does not rise, or drop immediately, inspect the cap and repair or replace as necessary.
(5) Diaphragm assembly inspection
Inspect the diaphragm assy on the rocker arm cover.
1) Loosen screws, remove the diaphragm assembly, and check for oil and contaminants between the diaphragm and the cover. If oil and contaminants enter into the diaphragm assembly, the diaphragm will not operate as designed.
2) Inspect the diaphragm rubber and spring for damage. If necessary, replace with new ones.
[Notice]
1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles such as combustion defect and so on occur.
2) At lubricating oil replacement or lubricating oil supply, the amount of lubricating oil isn't to be beyond the standard upper limit. If the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine, the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur.
Spring
Center plate
Diaphragm
Breather pipe
Intake silencer
Diaphragm cover
Rocker arm cover
Breather baffle
Baffle plate
(Breather system component)
(6) Adjust the tension of the alternator driving belt
Replace the alternator driving belt with new one every 1000 hours or four years, whichever comes first, even if there is no crack in the surface.
Refer to 2.2.2(4) for the procedure.
36
2. Inspection and Adjustment
(7) Retighten all major nuts and bolts.
Retighten the major nuts and bolts bellow by the standard tightening torques. (See the table in 4.5.)
1) Cylinder head bolts
2) Crankshaft pulley bolts
3) Fuel injection nozzle set bolts
4) Fuel pump gear set bolts
5) Fuel injection line sleeve nut
Retighten the following major bolts as requested.
1) Rod bolts
2) Flywheel set bolts
3) Metal cap bolts
(8) Adjust intake/exhaust valve clearance.
Refer to 2.2.2(5) for the procedure.
(9) Check/adjust the remote control operation.
Refer to 2.2.2(6) for the procedure.
(10) Adjust the propeller shaft alignment.
1) The rubber tension of the flexible engine mounts is lost after many hours' use. This leads to a drop in vibration absorption performance, and also causes centering misalignment of the propeller shaft.
(Refer to 5. "Flexible Engine Mount" in the installation manual for pleasure boat use.)
Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first.
2) After replacing the flexible engine mounts, check unusual noise and vibration of the engine and the boat hull with increasing the engine speed gradually and lowering it.
3) If there is unusual noise and/or vibration, adjust the propeller shaft alignment. (Refer to 6.4.5
"Centering the Engine" in the installation manual for pleasure boat use.)
37
2. Inspection and Adjustment
2.3 Adjusting the no-load maximum or minimum speed
1) After warming the engine up, gradually raise the speed and set it at the no-load maximum speed.
2) If the no-load maximum speed is out of the standard, adjust it by turning the high idle limiting bolt.
3) Then set the no-load minimum speed by adjusting the low idle limiting bolt.
Standards
No-load maximum
3325 ±25
(Unit : min
-1 )
No-load minimum
800 ±25
Remote control cable
High speed limiting bolt
Control lever
Cable joint
Fuel injection pump
Low speed limiting bolt
2.4 Sensor Inspection
2.4.1 Oil pressure switch
Disconnect the connector from the oil pressure switch.
Keep the voltammeter probes in contact with the switch terminal and cylinder block while operating the engine.
It is abnormal if circuit is closed.
Oil pressure switch
Cylinder block
(flywheel side)
Tester probes
(Continuity test)
2.4.2 Thermo switch
Place the thermo switch in a container filled with antifreeze or oil. Heat it while measuring the fluid temperature. The switch is normal if the voltammeter shows continuity when the fluid temperature is 97-103 deg C.
Thermometer
Tester probes
Hot water
Thermo switch
38
2. Inspection and Adjustment
2.5 Thermostat inspection
(1) Put the thermostat in a beaker with fresh water, and heat it on an electric stove. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8mm or more at 90 deg C Replace the thermostat if it not functioning normally.
Thermometer
Thermostat cover
Thermostat
Gasket
Thermostat
Gasket
Fresh water pump body
Valve opening
Temperature
75.0-78.0
(deg C)*
Full open lift
(Temperature)
(mm)
8 or more (90deg C)
* Valve opening temperature is carved on the flange.
(2) Normally, the thermostat should be inspected every 500 hours or operation, but, it should be inspected before this if the cooling temperature rises abnormally or white smoke is emitted for a long time after engine starting.
(3) Replace the thermostat every year or 2000 hours of operation (whichever comes first).
39
2. Inspection and Adjustment
2.6 Adjusting Operation
Perform the adjusting operation for an engine as follows after the maintenance job:
2.6.1 Preliminary Precautions
Before making a test run, make sure of the following points.
(1) Warm the engine up.
(2) Remove any precipitation from the F.O. filter. water separator, and F.O tank.
(3) Use only lube oil recommended by Yanmar.
(4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water.
(5) Provide good ventilation in the engine room.
2.6.2 Adjusting operation procedure
1) Supply the fuel oil, lubricating oil and cooling water.
Note:
Check the levels of the lubricating oil and cooling water again after test running (for about 10 minutes) and add as required.
2) Start the engine, and carry out idling at a low speed (700 to 900 min -1 ) for a few minutes.
3) Run in the engine for about five minutes at the rated speed (no-load). Check any water, fuel or lube oil leakage and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and exhaust gas color.
4) Adjust the no-load minimum and maximum speed. (Refer to 2.3.)
5) Perform loaded operation as required.
40
2. Inspection and Adjustment
2.6.3 Check Points and Precautions During Running
Step Item
1 Checks before operation
2 No load operation; warm up operation
3
4
5
Cruising (load) operation
Stopping the engine
Checks after stopping the engine
Instructions
1) Make sure that the sea cock is open.
2) Make sure there is enough lube oil and (fresh) cooling water.
3) Operate the remote control handle and check if the device connected to the engine works property.
1) When the lube oil temperature is raised to allow the engine to start, the pilot lamp goes off.
2) When the engine is started, check the following:
• There is no leakage of water, fuel and lube oil.
• Exhaust gas does not leak when the engine is started.
• here is no abnormal indication on the instrument panel.
• There is no abnormality in cooling water discharge, engine vibration. or engine sound.
3) To warm up the engine, operate at low speed for about 5 minutes, then raise the speed to the rated speed and then to max. speed.
Precautions
3) Lamp should go off when engine is running.
2)
• Fit leaks if any.
• Check the intake/ exhaust valves, fuel injection nozzle and cylinder head.
3) Do not raise the engine speed abruptly.
1) Do not operate the engine at full load yet, but raise the speed gradually for about 10 minutes until it reaches the rated speed.
2) Make sure that exhaust gas color and temperature are normal.
3) Check the instrument panel and see if the water temperature and oil pressure are normal.
1) Before stopping the engine, operate it at 650-700 min -1 for about 5 minutes.
2) Raise engine speed to 1,800 min -1 jut before stopping the engine and idle the engine for about
3-4 seconds.
1) Check again for water and oil leaks.
2) Make sure that no nuts and bolts are loose.
3) Close the sea cock and fuel cocks.
4) When the temperature is expected to fall below freezing, drain the seawater.
5) Turn off the battery switch.
1) Stopping the engine suddenly during high speed operation increases the temperature of engine parts.
2) This procedure prevents carbon from being deposited on the valve seats, etc.
1) Check the oil seal area.
2) Especially the engine installation bolts.
4) Drain from the seawater pump.
41
2. Inspection and Adjustment
2.7 Long storage
Observe the following instructions when the engine is to be stored for a long period without operation:
1) Do not drain cooling water in the cold season or before the long storage.
[NOTICE]
Negligence of adding anti-freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts.
2) Remove the mud, dust and oil deposit and clean the outside.
3) Perform the nearest periodic inspection before the storage.
4) Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
5) Disconnect the battery cable from the battery negative (-) terminal.
6) Cover the silencer, air cleaner and electric parts with PVC(Poly Vinyl Chloride) cover to prevent water and dust from depositing or entrance.
7) Select a well-ventilated location without moisture and dust for storage.
8) Perform recharging once a month during storage to compensate for self-discharge.
9) When storing an engine for long time, run the engine periodically according to the following procedure. Because the rust occurrence inside the engine, the rack agglutination of the fuel pump, and so on are likely to occur. (In case that the engine is equipped with a boat.) a) Replace the lube oil and the filter before the engine running.
b) Supply fuel if the fuel in the fuel tank was removed, and bleed the fuel system.
c) Confirm that there is the coolant in the engine.
d) Operate the engine at the low idling speed for about five minutes. (If it can be done, once a month)
42
3. Troubleshooting
3. Troubleshooting
3.1 Preparation before troubleshooting
If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life.
When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and prevent the recurrence of the trouble.
1) What’s the occurrence phenomenon or the trouble situation?
(e.g. Poor exhaust color )
2) Investigation of the past records of the engine
Check a client control ledger, and examine the history of the engine.
• Investigate the engine model name and the engine number. (Mentioned in the engine label.)
• Examine the machine unit name and its number in the same way.
• When was the engine maintained last time?
• How much period and/or time has it been used after it was maintained last time?
• What kind of problem was there on the engine last time, and what kind of maintenance was dane?
3) Hear the occurrence phenomenon from the operator of the engine in detail.
5W1H of the occurrence phenomenon : the investigation of when (when), where (where), who(who), what (what), why (why) and how (how)
• When did the trouble happen at what kind of time?
• Was there anything changed before the trouble?
• Did the trouble occur suddenly, or was there what or a sign?
• Was there any related phenomenon.
(e.g. Poor exhaust color and starting failure at the same time)
4) After presuming a probable cause based on the above investigation, investigate a cause systematically by the next troubleshooting guide, and find out the cause of sincerity.
43
3. Troubleshooting
3.2 Quick Reference Chart for Troubleshooting
It is important to thoroughly under stand each system and the function of all of the parts of terse systems.
A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause.
Begin by checking the most easily identifiable causes of difficulty. Where the cause of the difficulty is not readily apparent, make a thorough examination of the system from the very beginning, proceeding until the point of trouble can be determined. While experience is an important factor in pinpointing engine problems, careful study and understanding of the engine mechanism combined with good common sense will help you to rapidly become more expert at troubleshooting.
44
(II-1) Replace.
THE ENGINE SUDDENLY STOPS.
(II-2) Clean carefully to insure good working order.
Chart 1
TROUBLE AND TROUBLESHOOTING
(I-1) Add fuel oil and prime.
(I-2) Bleed air.
(I-3) Remove water from drain and fuel oil system and prime.
(I-4) Check and make necessary repairs.
(I-5) Clean.
(I-6) Replace.
(I-7) Check and make necessary repairs.
(I) Fuel oil supply cut off
(1) Insufficient oil in fuel oil tank (3) Water in fuel oil tank
(2) Air in fuel oil system and fuel injection pump
(4) Fuel oil cock closed
(5) Clogging of fuel oil filter
(6) Damage in fuel oil system
(II) Governor trouble
(7) Problem with fuel feeding pump
(1) Damage to governor spring
(2) Sticking of governor sleeve
(1) Loose lube oil pressure adjustment valve
(3) Leakage from lube oil safety valve
(4) Trouble with lube oil pump
(1) Seizure of moving parts
THE ENGINE
SUDDENLY STOPS.
(2) Clogging of lube oil filter
(2) Overloading due to insufficient
cooling water
(5) Relay operation triggered by low lube oil pressure
(III) Emergency stoppage device in operation
(III-1) Tighten adjustment valve.
(III-2) Clean.
(III-3) Tighten safety valve.
(III-4) Remove and repair or replace.
(III-5) Return to original condition.
(IV) Miscellaneous
(IV-1) Remove and repair or replace.
(IV-2) Disassemble and clean cooling water pump and check cooling water system.
Chart 2
TROUBLE AND TROUBLESHOOTING
(I-1) Bleed air.
(I-2) Disassemble and clean.
(I-3) Replace.
(I-4) Repair or replace.
(I-5) Replace.
(I-6) Tighten firmly.
CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE
(I -7) Disassemble and clean
and repair replace.
Trouble and Troubleshooting
(I-1) Check, repair or replace.
(I-2) Replace.
(I-3) Check, repair or replace.
(I-4) Adjust.
(I-5) Adjust.
(I) Uneven quantity of fuel oil injected
(1) Air in the fuel injection pump
(5) Damaged exhaust union packing
(2) Faulty operation of plunger
(3) Damaged plunger spring
(6) Loose pinion screw
(7) Faulty fuel injection
pump tappet
(4) Faulty fuel oil ejection valve
CYLINDER OUTPUT
IS UNEVEN
(1) Oil leakage in injection
system
(2) Damaged valve
spring
(3) Insufficient injection
pressure in injection
valves
(4) Irregular injection timing
(5) Sticking of injection valves
(II) Faulty fuel injection valve
(II-1) Check and repair.
(II-2) Replace.
(II-3) Adjust.
(II-4) Adjust.
(II-5) Clean.
(I) Faulty fuel injection pump
Chart 3
POOR EXHAUST COLOR
(II-1) Clean.
(II-2) Check, repair or replace.
(II-3) Adjust.
(II-4) Check, repair or replace.
(II-5) Clean.
(1) Faulty plunger operation (1) Injection opening is clogged
(2) Worn plunger (2) Sticking of valve needle
(3) Faulty ejection valve
(4) Uneven quantity of fuel injected
(5) Irregular fuel injection timing
(3) Low injection pressure
(4) Faulty spry condition
(5) Carbon deposit
(1) Clogged filter
POOR
EXHAUST
COLOR
(1) Overloading
(2) Too great a quantity of lube oil
(3) Carbon deposit in suction valves
(4) Dirty air cooler
(5) Poor quality fuel oil
(6) Clogging in exhaust system Cause
(III) Clogged intake air filter (IV) Miscellaneous
(III-1) Clean.
(II) Faulty fuel injection valve
(IV-1) Reduce load.
(IV-2) Adjust quantity of oil.
(IV-3) Clean.
(IV-4) Clean.
(IV-5) Reduce. with new oil.
(IV-6) Clean.
TROUBLE AND TROUBLESHOOTING
(I-1) Disassemble and clean.
(I-2) Repair or replace.
(I-3) Repair or replace.
(I-4) Replace.
(I-5) Repair.
(I-6) Adjust.
(I-7) Replace.
(I-8) Replace.
(I-9) Adjust to correct position.
(I-10) Reassemble.
(I-11) Check for oil leakage
and replenish.
(II-1) Review (I-1, I-11).
(II-2) Reduce load.
(II-3) Replace.
(II-4) Check oil level and adjust.
(II-5) Check water level and adjust.
(II-6) Change oil.
(II-7) Review manual.
TROUBLE WITH MARINE GEAR
(III -1) Replace.
(III -2) Replace.
Chart 4
(III -3) Eliminate dangerous rotation.
(I) Low clutch oil pressure (clutch slips)
(1) Cogging of filter
on suction side (7) Worn sliding parts of
forward/reverse conversion valve
(2) Worn oil pump
(3) Sticking of oil pressure
adjustment valve
(8) Damaged O-ring,
V-ring in oil pressure pipe
(4) Damage or old oil pressure
adjustment valve spring
(5) Damaged seal ring
(6) Incorrect positioning of
forward/reverse conversion valve
(11) Insufficient oil
(II) Overheating
(1) Clutch slippage due
to low oil pressure
speed valve handle
(2) Clutch slippage due
to overloading
(9) Low speed valve handle slips
(10) Poor assembly of low
(3) Damaged bearing
(4) Too much oil
(5) Problem with
oil cooler
(6) Poor quality or
inappropriate oil
(III) Abnormal noise
(2) Damaged bearing
(7) Poor operation of
low speed valve
(1) Excessive backlash
of gear
(3) Abnormal vibration
TROUBLE WITH
(1) Damaged holding
spring of pipe
(4) Phase slippage
(2) Foreign material
in pipe system
(3) Oil leakage where there
is remote control
(1) Not enough warp
in steel plate
(2) Damaged holding
spring of pipe
(3) Lube oil pressure
is too high
(4) Viscosity of lube
oil is too high
(1) Oil leakage
MARINE GEAR
(2) Clogged lube
oil filter
(3) Damaged or old lube oil
adjustment valve spring
(4) Sticking of lube oil
adjustment valve
(IV) Difficulty changing into forward, neutral, and reverse (V) Dragging (VI) Abnormal lube oil pressure
(IV-1) Replace.
(IV-2) Clean.
(IV-3) Replenish oil and check. Replace bellofrom.
(IV-4) Repair link system.
(V-1) Replace.
(V-2) Replace.
(V-3) Adjust lube oil adjustment valve.
(V-4) Change oil.
(VI-1) Check and repair.
(VI-2) Disassemble and clean.
(VI-3) Replace.
(VI-4) Repair or replace.
TROUBLE AND TROUBLESHOOTING
(I-1) Lap.
(I-2) Replace.
(II-1) Clean.
(II-2) Replace.
(II-3) Replace.
(II-4) Correctly install pump.
(II-5) Clean.
(II-6) Replace.
Chart 5
ROTATION IS NOT SMOOTH
(II-7) Bleed air and prime.
(II-8) Adjust.
(II-9) Adjust.
(I) Faulty operation of injection valve
(1) Impediment to valve
needle movement
(2) Damaged valve spring
(1) Damaged governor bearing
(2) Faulty operation
of governor link
(II) Uneven supply of fuel oil injected
(1) Faulty operation of
fuel pump plunger
(2) Damaged fuel pump plunger
(5) Clogging of fuel filter
(6) Damaged fuel cam
(7) Air in fuel injection system
(3) Damaged plunger spring
(8) Faulty operation of adjustment rack
(4) Inaccurate assembly of fuel injection pump
(9) Uneven amount of fuel to cylinders
ROTATION IS NOT
SMOOTH
(1) Overloading
(3) Sticking of governor sleeve
(2) Seizure of moving parts
(4) Faulty operation of
fuel oil adjustment (3) Clutch slippage
(III) Faulty operation of governor (IV) Miscellaneous
(III-1) Replace.
(III-2) Adjust.
(III-3) Clean.
(III-4) Disassemble, wash and repair.
(IV-1) Reduce load.
(IV-2) Disassemble, check and repair.
(IV-3) Check and adjust.
(II-1) Delay injection timing.
(II-2) Adjust standard injection pressure.
KNOCKING
Chart 6
TROUBLE AND TROUBLESHOOTING
(I-1) Increase injection pressure.
(I-2) Replace.
(I-3) Disassemble and lap.
(I-4) Disassemble and repair.
(I) Faulty fuel injection valve
(1) Low injection pressure
(3) Sticking of valve needle
(2) Damaged fuel valve spring
(4) Faulty injection spray
(II) Faulty fuel injected
(1) Early fuel injection
(2) Fuel pressure is too high
KNOCKING
(1) Excessive quantity of fuel
is ejected from fuel pump
(III) Excessive quantity of fuel injected each time
(1) Insufficient cooling water
(4) Poor quality fuel oil
(2) Excess piston clearance
(5) Water mixed in fuel oil
(3) Excess bearing clearance
(6) Incorrect pressure
(IV) Miscellaneous
(III-1) Adjust pump adjustment rack.
(IV-1) Check cooling water pump and lap valves.
(IV-2) Replace.
(IV-3) Replace.
(IV-4) Replace with good fuel oil.
(IV-5) Replace with good fuel oil.
(IV-6) Check and repair.
TROUBLE AND TROUBLESHOOTING
(I-1) Tighten.
(I-2) Repair using sandpaper or replace.
(I-3) Replace.
(I-4) Repair using sandpaper and
then grease.
(I-5) Adjust.
(I-6) Adjust.
(I-7) Replace.
(II-1) Tighten.
(II-2) Repair using sandpaper.
(II-3) Replace.
(II-4) Repair using sandpaper
(Type 500 600).
(II-5) Replace.
(II-6) Undercut and repair or replace.
(II-7) Replace.
(II-8) Replace with thicker or shorter wire.
(II-9) Charge.
Chart 7
(III-1) Prime well.
(III-2) Adjust.
(III-3) Clean out matter causing clogging.
(III-4) Add fuel to fuel tank.
(III-5) Open cock.
(III-6) Clean.
(III-7) Disassemble and repair or replace.
(III-8) Drain water from fuel system
and prime.
TROUBLE WITH STARTING
(IV-1) Lap.
(IV-2) Lap.
(IV-3) Replace.
(IV-4) Clean or replace.
(IV-5) Adjust.
(I) Pinion gears do not mesh
(1) Loose battery engage
magnet terminal
(2) Faulty connection
in starting switch
(3) Cut battery engage
magnet coil
(4) Rough cap movement
(1) Worn plunger
(2) Damaged
plunger spring
(5) Edges of gear
teeth misshapen
(6) Faulty positioning of
pinion and ring gears
(7) Seizure of
starter metal
(5) Air inside pump
(II) Ring gears do not mesh
(1) Loose battery
starter terminal
(2) Faulty connection in
engage magnet switch
(3) Worn brushes
(4) Commutator
rough and dirty
(III) Fuel oil not injected
(1) Imperfect priming of fuel oil system
(IV) Faulty fuel injection valve
(5) Cut starter coil
(6) Worn commutator
(7) Slippage of starter clutch
(8) Excessive resistance
between battery and starter
(2) Injection cut off due to faulty governor
(3) Clogging of fuel inlet filter
(4) Insufficient fuel oil in tank
(9) Insufficient battery charge
(5) Fuel oil tank cock closed
(6) Clogging in fuel oil pipe
(7) Damaged fuel oil supply pump
(8) Water in fuel oil tank
(1) Faulty valve seat
(2) Sticking of valve needle
(3) Worn valve needle
(4) Clogged outlet
(5) Low injection pressure
STARTING
(3) Plunger sticks
(4) Oil leakage from exhaust valve
(6) Damaged exhaust valve spring
(1) Fuel injection pump
timing irregular
(2) Loose high pressure fuel pipe
(3) Damaged high pressure fuel pipe
(4) Air in high pressure fuel pipe
(1) Air leakage from suction/exhaust valves
(2) No tappet clearance
(3) Faulty gasket packing
(4) Upper part of cylinder liner worn
(5) Worn piston ring
(6) Piston ring sticks
(7) Insufficient tightening of head bolts
(8) Damaged valve spring
TROUBLE
(1) Incorrect thickness
of gasket packing
(2) Faulty installation of
governor ring and lever
(3) Governor handle is in stop position
(4) Faulty engine starter
(5) Clogging of suction/exhaust pipes
(V) Faulty fuel injection pump (VI) Faulty fuel injection system (VII) Leakage of pressurized air (VIII) Miscellaneous
(V-1) Replace plunger and barrel as a unit.
(V-2) Replace.
(V-3) Disassemble and repair or replace.
(V-4) Lap valves.
(V-5) Bleed air.
(V-6) Replace.
(VI-1) Adjust.
(VI-2) Tighten firmly.
(VI-3) Replace.
(VI-4) Bleed air.
(VII-1) Lap valves.
(VII-2) Adjust .
(VII-3) (VII-4) (VII-5) Replace.
(VII-6) Disassemble and
repair or replace.
(VII-7) Tighten tightening
nuts uniformly.
(VII-8) Replace.
(VII-1) Replace.
(VII-2) Adjust .
(VII-3) Move governor handle to acceleration position.
(VII-4) Check and repair.
(VII-5) Clean.
INSUFFICIENT POWER OUTPUT
(III-1) Replace.
(III-2) Repair.
Chart 8
TROUBLE AND TROUBLESHOOTING
(I-1) Replace.
(I-2) Disassemble and repair or replace.
(I-3) Lap valves.
(I-4) Tighten firmly.
(I-5) (I-6) Adjust.
(I-7) (I-8) Clean.
(I-9) Replace.
(I-10) Repair.
(II-1) Clean nozzle hole or replace.
(II-2) Lap or replace.
(II-3) Lap or replace.
(II-4) Tighten firmly.
(II-5) Replace.
(II-6) lean.
(I) Amount of oil supply from fuel injection pump inadequate
(1) Worn plunger
(2) Sticking of plunger
(3) Oil leakage from exhaust valve
(4) Oil leakage from joint of
high pressure pipe
(II) Amount of fuel injection inadequate
(6) Inaccurate positioning
of adjustment rack
(7) Clogging of fuel filter
(8) Clogging of fuel oil pipe
(9) Damaged valve spring
(1) Clogging of nozzle hole
(2) Faulty valve seat
(3) Sticking of valve needle
(4) Loose high pressure pipe
(5) Worn valve needle
(5) Faulty adjustment of fuel pump
(10) Faulty supply pump (6) Clogging of filter
(1) Leakage of gas from
suction/exhaust valves
(2) Inadequate tapper
clearance
(3) Worn upper part
of cylinder liner
(4) Worn piston ring
(5) Sticking of piston ring
(1) Early injection
(2) Late injection
(III) Faulty governor
(1) Damaged governor bearing
(2) Inaccurate length
of governor link
INSUFFICIENT
POWER OUTPUT
(1) Clogging of air filter
(1) Poor quality fuel oil
(2) Clogging of exhaust line
(3) Seizure of moving parts
(4) Insufficient cooling water
(5) Insufficient lube oil supplied
(IV) Leakage of pressurized gas from inside cylinder (V) Irregular fuel injection timing (VI) Clogged intake air filter (VII) Miscellaneous
(IV-1) Lap valves.
(IV-2) Adjust.
(IV-3) Replace.
(IV-4) Replace.
(IV-5) Disassemble and repair or replace.
(V-1) Adjust timing to
delay injection.
(V-2) Adjust timing to
speed injection.
(VI-1) Clean.
(VII-1) Replace with good fuel oil.
(VII-2) Clean.
(VII-3) Disassemble, check and repair.
(VII-4) Lap cooling water pump suction/exhaust valves.
(VII-5) Disassemble and clean lube oil pump and filter.
TROUBLE AND TROUBLESHOOTING
(I-1) Tighten nuts.
(I-2) Tighten nuts and insert pins.
(I-3) Remove adjustment liner and adjust aperture,
or replace.
(I-4) Check teeth, shaft, and pushrod of gear
for wear. Replace where necessary.
(II-1) Tighten adjustment valve.
(II-2) Check and repair.
(II-3) Clean.
(II-4) Repair.
Chart 9
MISCELLANEOUS TROUBLE
(III-1) Clean.
(III-2) Add cooling water.
(III-3) Disassemble and repair or replace.
(III-4) Tighten adjustment valve.
(III-5) Tighten safety valve.
(III-6) Change lube oil.
(III-7) Add lube oil.
(III-8) Replace.
(I) Abnormal noise
(1) Loose flywheel installment bolt
(2) Loose crank pin bearing bolt
(3) Worn crank pin metal
(4) Faulty gear meshing
(II) Low fuel oil pressure
(1) Loose pressure adjustment
(2) Damaged supply pump
(3) Clogged filter
(4) Leaky pipe
(III) Low lube oil pressure
(1) Clogged lube oil filter
(5) Oil leakage from pump safety valve
(2) Lube oil temperature is too high
(6) Inadequate viscosity of lube oil
(3) Trouble with lube oil pump
(7) Insufficient amount of lube oil
(4) Loose pressure adjustment valve
(8) Faulty pressure gauge
(1) Cooling water temperature
has risen
(2) Overloading
(3) Faulty lube oil
temperature
adjustment valve
(IV) Lube oil temperature is too high
(1) Insufficient amount of cooling water
(2) Trouble with cooling water pump
(3) Amount of water returning
is too great
(4) Clogging in cooling
water system
(6) Overloading
(2) Trouble with cooling water pump
(3) Cooling water lift is too great
MISCELLANEOUS
TROUBLE
(1) Clogging in cooling water system
(5) Air in cooling water (5) Engine outlet not constricted.
(6) Water leakage from
cooling water joints.
(4) Air in cooling water
(V) Cooling water temperature is too high (VI) Cooling water pressure is too low
(IV-1) Adjust the amount of returning water or
check the cooling water pump and lap valves.
(IV-2) Reduce load.
(IV-3) Clean and adjust.
(V-1) Open closed parts.
(V-2) Check pump and repair.
(V-3) Adjust amount of returning water.
(V-4) Clean.
(V-5) Check suction opening.
(V-6) Reduction load.
(VI-1) Clean.
(VI-2) Check pump and repair.
(VI-3) Lessen lift or replace pump.
(VI-4) Check suction opening.
(VI-5) Eliminate causes for high cooling water
temperature and constrict.
(VI-6) Check and repair.
3. Troubleshooting
3.3 Troubleshooting (Concerning engine and fuel injection equipment)
Malfunctions
The engine does not operate
1. Fuel Oil is not injected from the injection pump
2. Injection timing is incorrect
3. The nozzle does not operate
4. The engine operates. but only for short time
5. The engine “knocks”
Causes Remedies
1. There is no fuel oil in the fuel tank
2. The fuel line from the fuel tank is blocked
3. The fuel is clogged
4. There is air in the fuel filter or the pump chamber
5. The accelerator linkage is not properly connected
6. The magnet valve wiring is broken or its armature is
Sticking
7. The feed pump blades are sticking, and therefore not operating
8. The drive gear or woodruff key is broken
1. The drive gear or belt connections are incorrect
2. The injection pump is incorrectly installed on the engine
3. The roller holder assembly’s roller or pin is worn excessively
4. The plunger is worn excessively
1. The nozzle or nozzle holder is functioning incorrectly
1. The pipe(s) to the injection pump is blocked. or the fuel filter is clogged
2. The fuel oil contains air or water
3. The feed pump’s delivery quantity (or pressure) is insufficient
1. The injection timing is too advanced
2. The nozzle or nozzle holder is functioning incorrectly
Supply fuel and bleed the system
Clean or replace
Clean or replace
Bleed the system
Repair
Repair or replace
Repair or replace
Replace
Repair
Repair and adjust injection timing
Replace the assembly
Replace the distributor assembly
Inspect. then repair or replace
Clean or replace the pipe(s) or fuel filter
Bleed of air or replace the fuel oil
Repair or replace
Readjust the timing
Inspect. then repair or replace
53
3. Troubleshooting
Malfunctions
The engine exhaust contains smoke and the engine “knocks”
The engine output is unstable
Insufficient output
1. The injection quantity is insufficient
Causes
1. The injection timing is incorrect
2. The nozzle or nozzle holder is functioning incorrectly
3. The injection quantity is excessive
Remedies
Readjust the timing
Inspect, then repair or replace
Readjust
1. The fuel filter element is clogged and fuel oil delivery is poor
2. The amount of fuel or pressure delivered by the feed pump is too little
3. The injection pump is sucking air
4. The regulating valve is stuck in the open position
5. The plunger is sticking and does not travel its full stroke
6. The plunger spring IS broken
7. The control sleeve is not sliding smoothly
8. The governor lever is not operating properly or is worn excessively
9. The delivery valve spring is broken
10. The delivery valve is not sliding properly
11.The nozzle or the nozzle holder is not functioning properly
12.The injection timing is incorrect
Clean or replace
Inspect and repair
Inspect and repair
Replace
Replace the distributor assembly
Replace
Repair or replace
Repair or replace
Replace
Repair or replace
Inspect, and then repair or replace
Readjust
1. The specified full-load injection quantity is not delivered
2. The control lever is not reaching the maximum speed position
3. The governor spring is weak and therefore the governed speed is too low
4. The plunger is worn
5. The delivery valve seating portions are damaged
Readjust
Readjust
Replace
Replace the distributor assembly
Replace
Readjust 2. The injection timing is too advanced and the engine is
“knocking”
3. The injection timing is too retarded and the engine is overheating or the exhaust contains smoke
Readjust
54
3. Troubleshooting
Malfunctions
4. The nozzle or the nozzle holder is not functioning properly
The engine cannot reach its maximum speed
Causes Remedies
Inspect and then repair or replace
1. The governor spring is too weak or is improperly adjusted
2. The control lever is not reaching the maximum-speed position
3. The nozzle’s injection operation is poor
Readjust or replace
Readjust
Repair or replace
The engine’s maximum speed is too high
1. The governor spring is too strong or is improperly adjust
2. The governor flyweights or governor sleeve movement is not smooth
Readjust or replace
Repair or replace
Idling is unstable 1. The injection quantities are not uniform (the delivery valve is not operating properly)
2. The governor’s idling adjustment is improperly adjusted
3. The plunger is worn
4. The plunger spring IS broken
5. The rubber damper is worn.
6. The governor lever shaft pin is worn excessively
7. The feed pump blades are not operating properly
8. The regulating valve is stuck in the open position
9. The fuel filter element is clogged and therefore fuel oil delivery is poor
10.The nozzle or the nozzle holder is not functioning properly
Inspect or replace
Readjust
Replace the distributor assembly
Replace
Replace
Replace
Repair or replace
Replace
Clean or replace
Inspect and then repair or replace
55
3. Troubleshooting
3.4 Troubleshooting by measuring Compression Pressure
Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors:
1) Degree of clearance between piston and cylinder
2) Degree of clearance at intake/exhaust valve seat
3) Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnormality in the engine.
(1) Compression pressure measurement method
1) After warming up the engine, remove the fuel injection pipe and valves from the cylinder to be measured.
2) Crank the engine before installing the compression gage adapter.
a) Perform cranking with the stop handle at the stop position (no injection state).
b) See 12.2-18 in Chapter 12 for the compression gage and compression gage adapter.
3) Install the compression gage and compression gage adapter at the cylinder to be measured.
a) Never forget to install a gasket at the tip end of the adapter.
4) With the engine set to the same state as in 2)a), crank the engine by the starter motor until the compression gage reading is stabilized.
Compression gage
(Measurement of the compression pressure)
(2) Standard compression pressure
Engine compression pressure list (reference value)
Compression pressure at 250 min
-1
MPa (kgf/cm
2
)
Standard Limit
3.63±0.1 (37±1) 2.94±0.1 (30±1)
Deviation among cylinders
MPa (kgf/cm 2 )
0.2±0.3 (2±3)
56
3. Troubleshooting
(3) Engine speed and compression pressure (for reference)
3JH4E
40
25
20
35
30
4
3
2
200 250 300 350 400
Engine speed (min
-1
)
(4) Measured value and troubleshooting
When the measured compression pressure is below the limit value, inspect each part by referring to the table below.
No.
1
2
3
4
5
6
Item Cause Corrective action
• Air cleaner element • Clogged element
• Broken element
• Defect at element seal portion
• Valve clearance
• Clean the element.
• Replace the element.
• Excessive or no clearance • Adjust the valve clearance.
(See 3.5 in Chapter 3.)
• Valve timing • Incorrect valve clearance
• Cylinder head gasket
• Gas leak from gasket
• Adjust the valve clearance.
(See 3.5 in Chapter 3.)
• Replace the gasket.
• Retighten the cylinder head bolts to the specified torque.
(See 4.2(2)12) in Chapter 4.)
• Intake / exhaust vale
• Valve seat
• Piston
• Piston ring
• Cylinder
• Gas leak due to worn valve seat or foreign matter trapping
• Sticking valve
• Gas leak due to scratching or wear
• Lap the valve seat.
(See 4.2(6) in Chapter 4.)
• Replace the intake/exhaust valve.
• Perform honing and use an oversized part.
(See 4.4(5)-(5-1), (5-4) and (6) in
Chapter 4.)
57
4. Disassembly and Reassembly
4. Disassembly and Reassembly
4.1 Disassembly and Reassembly Precautions
(1) Disassembly
• Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary.
• Be careful to keep all disassembled parts in order.
• Prepare disassembly tools.
• Prepare a cleaner and cleaning can.
• Clear an adequate area for parts and prepare a container(s)
• Drain cooling water (seawater, fresh water) and lube oil.
• Close the Kingston cock
(2) Reassembly
• Sufficiently clean and inspect all parls to be assembled.
• Coat sliding and rotating parts with new engine oil when assembling.
• Replace all gaskets and O-rings.
• Use a liquid packing agent as necessary to prevent oil/water leaks.
• Check the oil and thrust clearances. etc. of parts when assembling
• Make sure you use the correct bolt/nut/washer.
• Tighten main bolts/nuts to the specified torque. Be especially careful not to over tighten the aluminum alloy part mounting bolts.
• Align match marks (if any) when assembling. Make sure that the correct sets of parts are used for bearings, pistons, and other parts where required.
58
Wrench
Wrench
Wrench
Screwdriver
4. Disassembly and Reassembly
4.2 Disassembly and Reassembly Tools
The following tools are required when disassembling and reassembling the engine.
Please use them as instructed.
4.2.1 General Handtools
Name of tool
Wrench
Illustration Remarks
Size : 10 x 13
Size : 12 x 14
Size : 17 x 19
Size : 22 x 24
Steel hammer Local supply
59
4. Disassembly and Reassembly
Name of tool
Copper hammer
Illustration
Mallet
Nippers
Pliers
Offset wrench
Local supply
Remarks
Local supply
Local supply
Local supply
Local supply 1 set
Box spanner Local supply 1 set
Scraper Local supply
60
Name of tool
Lead rod
File
Illustration
4. Disassembly and Reassembly
Local supply
Remarks
Local supply 1set
Rod spanner for hexagon socket head screws
Stariing Pliers
Hole type
Shaft type
61
S - 0
Local supply
Size : 6 mm
8 mm
10 mm
Local supply
S = Hole type
H = Shaft type
4. Disassembly and Reassembly
4.2.2 Special Handtools
Name of tool
Piston pin insertion/ extraction tool
Illustration
20 80
Remarks
(Piston pin extractor)
(Extraction of piston pin)
(Insertion of piston pin)
Connecting rod small end bushing insertion/extraction tool
20 80
(Extraction)
Intake and exhaust valve insertion/ extraction tool
20 75
Lubricating oil No.2 filter case remover
62
Name of tool
Piston ring compressor
Piston ring replacer
(for removal / installation of piston ring)
Valve lapping tool
(Rubber cap type)
Illustration
4. Disassembly and Reassembly
Remarks
Valve lapping powder
Feeler gauge
Pulley puller
(Local supply)
63
(Removing the coupling)
4. Disassembly and Reassembly
Name of tool
Press tool 1 for filler neck
1
Illustration
2
105
89
Remarks
-
Press tool 2 for filler neck copper tube
(Tool 1)
30 30
170
Chamfer
(Tool 2)
Stem seal insertion
(for inserting stem seal) d1
16.2
d2 d3 L1
22 13.5
18.8
L2
65 mm
L3
4 d
2 d
1
L
1
L
2 d
3 d
1 d
2
L
3
L
1
L
2
-
-
64
4.2.3 Measuring Instruments
Name of tool
Vernier calipers
Illustration
Micrometer
Cylinder gauge
Thickness gauge
Torque wrench
Nozzle tester
4. Disassembly and Reassembly
Remarks
0.05mm
0-150mm
0.01mm
0-25mm
25-50mm
50-75mm
75-100mm
100-125mm
125-150mm
0.01mm
18-35mm
35-60mm
50-100mm
0.05-2mm
128 N•m
(0-13kgf•m)
0-49 Mpa
(0-500kgf/cm 2 )
65
4. Disassembly and Reassembly
4.2.4 Other material
Liquid gasket
Items
Three Bond
No.1
TB1101
Three Bond
No.2
TB1102
Three Bond
No.3
TB1103
Three Bond
No.4
TB1104
Adhesive
Seal Tape
O-ring kit
EP lubricant
(molybdenum disulfate)
Usual Contents
200g
(1kg also available)
200g
(1kg also available)
150g
Features and application
Non-drying liquid gasket; solvent less type, easy to remove, superior in seawater resistance, applicable to various mating surfaces.
Non-drying liquid gasket; easy to apply, superior in water resistance and oil resistance, especially superior in gasoline resistance.
Drying film, low viscosity and forming of thin film, appropriate for mating surface of precision parts.
Three Bond
No.10
TB1211
Three Bond
TB1212
Three Bond
TB1401
200g
(1kg also available)
100g
100g
200g
Semi-drying viscoelastic material, applicable to nonflat surface having many indentations and protrusions, superior in heat resistance, water resistance, and oil resistance.
Solvent-less type silicone-base sealant, applicable to high temperature areas. (-50°C to 250°C)
Silicone-base, non-fluid type, thick application possible.
Prevention of loose bolts, gas leakage, and corrosion. Torque required to loosen bolt: 10 to 20% larger than tightening torque.
Excellent adhesive strength locks bolt semipermanently.
Lock tight
SUPER
TB1324
50g
Brand name
(LOWCOL
PASTE)
Brand name
(PASTE
SPRAY)
Brand name
(MOLYPASTE)
5m round tape Sealing material for threaded parts of various pipes.
Ambient temperature range: -150°C to 200°C
Ø 1.92-m dia.:1
Ø 2.42-m dia.:1
Ø 3.12-m dia.:1
Ø 3.52-m dia.:1
Ø 5.72-m dia.:1
O-ring of any size can be prepared, whenever required.
(Including adhesive, release agent, cutter, and jig)
50g For assembly of engine cylinders, pistons, metals shafts, etc.
Spray type facilitates application work.
330g
50g Prevention of seizure of threaded parts at high temperature.
Applicable to intake and exhaust valves. (stem, guide, face)
66
4. Disassembly and Reassembly
Scale solvent
Antirust
Anti freeze
Items
Cleaning agent
Scale solvent
Neutralizer
(caustic soda) pH test paper
Usual Contents
1 box
(4 kg × 4 removers)
1 box
(2 kg × 4 neutralizers)
Features and application
• The scale solvent removes scale in a short time.
(1 to 10 hours)
• Prepare water (seawater is possible) in an amount that is about 10 times the weight of the solvent. Mix the solvent with water.
• Just dipping disassembled part into removes scale.
To shorten removal time, stir remover mixture.
• If cleaning performance drops, replace remover mixture with new remover mixture.
• Neutralize used mixture, and then dispose of it.
To judge cleaning performance of mixture, put pH test paper into mixture. If test paper turns red, remover mixture is still effective.
Add antirust to fresh water system. Then operate engine for approximately 5 minutes. Antirust will be effective for 6 months.
Add antirust to fresh water system at the cold area to engine operate.
• The cleaning agent removes even carbon adhering to disassembled parts.
• If a cleaning machine is used, prepare 4 to 6% mixture of 60° to 80° to ensure more effective cleaning.
67
4. Disassembly and Reassembly
Items
Cleaning agent for turbocharger
Usual Contents
4L x 4
18L x 1
15sets : 1,
500cc x 6
Features and application
Special cleaning agent that requires no water, specially designed for blower of turbocharger and inter cooler.
[Notice]
It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work.
Before providing service, observe the cautions below:
1) Build up each gasket equally.
2) For a bolt hole, apply liquid gasket to the inside surface of the hole.
3) Conventionally, Three Bond TB1104(gray) or Three Bond
TB1102 (yellow) is used for paper packing though single use of one of these bounds is not effective.
4) If conventional packing is used, do not use liquid packing.
Oil pan mating surface
Buildup of TB1212
68
4. Disassembly and Reassembly
4.2.5 Measuring Instruments
No.
Name of tool
1 Dial gauge
Use
Measures shaft bending, distortions of levelness, and gaps.
Illustration
2 Test indicator
3 Magnetic stand
Measures narrow and deep places which cannot be measured with dial gauge.
Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles.
4 Micrometer
5 Cylinder gauge
6 Vernier calipers
7 Depth micrometer
8 Square
Measures the outer diameter of the crank shaft, piston, piston pin, etc.
Measure the inner diameter of the cylinder liner and rod metal.
Measures various outer diameters, thicknesses, and widths.
Measures sinking of valves.
Measures distortion in position of springs and perpendicularity of parts.
69
4. Disassembly and Reassembly
No.
9 V Block
Name of tool Use
Measures shaft distortion.
Illustration
10
11
12
Torque wrench
Thickness gauge
Cap tester
Used to tighten bolts and nuts to standard torque.
Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling.
Check for leakage in the fresh water system.
13 Battery current tester
14 Nozzle tester
Checks density of antifreeze and charging condition of battery fluid.
Checks the shape and pressure of spray emitted from the fuel injection valve at the time of injection.
15 Digital thermostat Measures temperature of various parts.
Float abcdefghijklmn abcdefghijklmn
70
4. Disassembly and Reassembly
No.
16 Rotation gauge
Name of tool
Contact type
Use
Measures rotation speed by placing at the indentation hole of the revolving shaft.
Illustration
Photoelectric type
Measures rotation speed by using a reflector mark which is placed on the exterior of the revolving shaft.
Revolving shaft
Reflection mark
High pressure fuel pipe clamp type
Measures rotation speed without reference to revolving shaft center or the exterior of the revol.
17 Circuit tester Measures the resistance, voltage, and continuity of the electric circuit.
18 Compression gauge Measures the pressure of the compression.
Gauge set code No.
TOL-97190080
Adapter code No.
119802-92950
71
4. Disassembly and Reassembly
4.3 Disassembly and Reassembly
4.3.1 Disassembly
• Preparation on a boat
For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship.
1) Remove the remote control cable (from engine and marine gearbox).
2) Unplug the extension cord for the instrument panel from the engine.
3) Remove the wiring between the starting motor and the battery.
4) Remove the exhaust rubber hose from the mixing elbow.
5) Remove the rubber hose connecting the coolant recovery tank to the filler cap.
6) Remove the seawater inlet hose for the seawater pump (after making sure the seacock is closed).
7) Remove the fuel oil inlet rubber hose from the fuel feed pump.
8) Remove the body fit (reamer) bolts and disassemble the propeller shaft coupling and thrust shaft coupling.
9) If a driven coupling is mounted to the front drive coupling, disassemble.
10) Remove the flexible mount nut, lift the engine, and remove it from the engine base.
(Leave the flexible mount attached to the engine base.)
• Disassembling an engine in a workshop
(1) Drain cooling water
1) Open a seawater drain cock to drain the seawater.
2) Open a drain cock on the cylinder body to drain the fresh water from the cylinder head and cylinder body.
3) Open a fresh water drain cock on the lower part of the coolant tank to drain the fresh water.
4) Open a fresh water drain cock on the lower part of the fresh water pump to drain the fresh water.
Fresh water pump Coolant tank
Drain cock for fresh water
Drain cock for seawater
Drain cock for fresh water
Seawater pump
Flywheel housing Drain cock for fresh water
(2) Drain lube oil
1) Remove the pipe coupling bolt, which holds the lube oil dip stick guide, and drain the lube oil from the engine.
2) Remove the drain plug on the lower part of the crank case control side, and drain the lube oil from the marine gearbox.
[NOTE: ]
If a lube oil supply/discharge pump is used for the engine, the intake hose is placed in the dip stick guide, and for the clutch side (gearbox) it is placed in the oil hole on top of the case. (Refer to 2.2.2(2)
& (3) )
72
4. Disassembly and Reassembly
(3) Removing (electrical) wiring
Remove the wiring from the engine. (Refer to 2.2.4(9) )
(4) Removing the fuel filter & fuel pipe
1) Remove the fuel pipes (fuel filter-fuel feed pump, fuel filter-fuel injection pump and fuel nozzle-fuel filter)
2) Remove the fuel filter.
Fuel nozzle
Air bleeding bolt
To fuel tank
Fuel filter
Fuel injection pump
Fuel feed pump
(5) Removing the intake silencer
1) Remove the breather hose attached to the intake silencer- rocker arm cover.
2) Remove the intake silencer from intake manifold.
Intake silencer
Clamp
Clamp
Breather hose
Clamp
Rocker arm cover
Intake manifold
Clamp
Intake hose
(Removing intake silencer)
73
4. Disassembly and Reassembly
(6) Removing the mixing elbow
1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow.
2) Remove the mixing elbow from the exhaust manifold.
Seawater
(7) Removing the starting motor
Remove the starting motor from the flywheel housing.
L-type mixing elbow
Gasket
Exhaust manifold
Flywheel housing
Starting motor
(Removing starting motor)
(8) Removing the alternator
1) Loosen the alternator adjuster bolt and remove the
V-belt.
2) Removing the adjuster from the fresh water pump, and remove the alternator from the gear case (with distance piece).
Adjuster bolt
Fresh water pump
Adjuster
Alternator
Distance piece
Gear case
74
4. Disassembly and Reassembly
(9) Removing the cooling water pipe (seawater/ fresh water)
1) Remove the seawater pipe (seawater pump-heat exchanger).
2) Remove the fresh water pipe (fresh water pump- heat exchanger. exhaust manifold-fresh water pump).
3) Remove the fresh water pipe (cylinder block-lube oil cooler, lube oil cooler-fresh water pump).
Heat exchanger
Mixing elbow
Heat exchanger
Exhaust manifold
Fresh water pump
From lube oil cooler
Seawater pump
(Fresh water pipe)
Seawater inlet
(Seawater pipe)
(10) Removing the heat exchanger (exhaust manifold, fresh water tank unit)
Remove the heat exchanger and gasket packing.
(11) Removing the seawater pump
1) Pull out the bearing mounts, receptacles from the seawater pump mounting side and from the opposite side of the gear case.
2) Remove the seawater pump.
75
4. Disassembly and Reassembly
(12) Removing the lube oil filter and lube oil cooler
1) Remove the fresh water pipe (cylinder block-lube oil cooler, lube oil cooler outlet)
2) Remove the lube oil filter from the lube oil cooler.
3) Remove the lube oil cooler nut and lube oil cooler.
Loosen the bolts for the filter bracket and remove the filter bracket.
4) Remove the lube oil dipstick and guide.
Cylinder block
Joint
Clamp
Fresh water
Filter bracket
Gasket To fresh water pump
Drain cock
Clamp
Bolt
Clamp
Lube oil cooler
Lube oil cooler nut
Lube oil filter
(Lube oil filter and cooler)
(13) Removing the fuel injection pipe
1) Remove the fuel injection pipe retainer.
2) Loosen the cap nuts on both ends of the fuel injection pipe and remove the fuel injection pipe.
3) Remove the fuel return pipe (fuel nozzle-fuel oil filter)
No.1
No.2
Fuel injection pipe
No.3
Fuel injection pipe retainer
Clamp
No.1
No.2
Fuel injection nozzle
No.3
Fuel return pipe
Fuel injection pump
(14) Removing the intake manifold
Remove the intake manifold and gasket.
(15) Removing the fresh water pump
Remove the fresh water pump and gasket.
Cylinder head
Gasket
O-ring
Fresh water pump
76
(16) Removing the fuel injection nozzles
Remove the bolt for the fuel nozzle retainer, and pull out the fuel nozzle retainer and fuel injection nozzle.
NOTE:
If the fuel nozzle protector stays in the cylinder head, make a note of the cylinder number and be sure to remove it when disassembling the cylinder head.
Bolt
Washer
Fuel nozzle retainer
Cylinder head
4. Disassembly and Reassembly
Fuel injection nozzle
Fuel nozzle protector
Fuel injection seat
(Fuel injection nozzle)
(17) Remove the fuel injection pump
1) Loosen the nut for fuel pump drive gear, and pull out the fuel pump drive gear /flange assembly with an extraction tool.
2) Remove the fuel injection pump and O-ring from the gear case flange.
(18) Removing the rocker arm shaft assembly
1) Remove the rocker arm cover.
2) Remove the bolts(s) for the rocker arm shaft support, and remove the entire rocker arm shaft assembly.
3) Pull out the push rods.
(19) Removing the cylinder head
1) Loosen the cylinder head bolts with a torque wrench, and remove the cylinder head.
2) Remove the cylinder head gasket.
(20) Removing the marine gearbox
Loosen the bolts for the clutch case flange, and remove the gearbox assembly
(21) Removing the flywheel
Loosen the flywheel bolts and remove the flywheel.
NOTE:
Be careful not to scratch the ring gear.
Bolt
Flywheel
Flywheel housing
77
(Removing flywheel)
4. Disassembly and Reassembly
(22) Turning the engine over
1) Place a wood block of appropriate size on the floor, and stand up the engine on the flywheel housing.
2) Remove the engine mounting feet.
(23) Removing the crankshaft V-pulley
Loosen the bolt tightening the crankshaft V-pulley and remove the crankshaft V-pulley with an extraction tool.
(24) Removing the oil pan
Remove the oil pan and spacer..
Gear case
Bolt
Washer
Crankshaft V-pully
Oil pan
Wood block
(25) Removing the lube oil inlet pipe
Remove the lube oil inlet pipe and gasket.
(26) Removing the gear case
Loosen the gear case bolts, and remove the gear case from the gear case flange.
Flywheel housing
Gear case flange
Gasket Bolt
Cylinder block
Lube oil inlet pipe
(27) Removing the lube oil pump
Remove the lube oil pump from the gear case.
Lube oil pump cover
Outer rotor
Inner rotor
Gear case
Pressure control valve
Oil seal
(Lube oil pump)
78
(28) Removing the idle gear
Loosen the three bolts holding the idle gear and pull out the idle gear and shaft.
4. Disassembly and Reassembly
Bolt
Idle gear shaft
Idle gear
(29) Removing the camshaft
1) Push up tappet by turning a camshaft to remove it from the cylinder block easily.
2) Loosen the thrust metal bolts through the holes of the camshaft gear, and remove.
3) Pull out the camshaft gear and camshaft assembly from the cylinder block.
NOTE:
The camshaft gear and camshaft are shrunk fit They must be heated to 180-200°C to disassemble.
(30) Removing the pistons and connection rods
1) Loosen the rod bolts and remove the large end cap.
2) Push the connecting rod and pull out the piston & connecting rod assembly.
NOTE:
Place a tool for the piston cooling nozzle to make sure the nozzle position does not change and it does not get scratched.
Connecting rod
Piston
Rod bolt
Large end cap
Crankpin bearing
(Removing piston and connecting rod)
79
4. Disassembly and Reassembly
(31) Removing the gear case flange
1) Remove the gear case flange from the cylinder block.
2) Remove the O-rings from the lube oil passage.
NOTE
1) When mounting the gear case flange, match up the two knock pins for cylinder block.
2) Be sure to coat the O-rings for the cylinder block lube oil passage with grease when assembling, so that it does not get out of place.
Liquid gasket
Gear case flange
O-ring
Knock pin
(Removing gear case flange)
(32) Loosening the main bearing bolts.
Loosen the main bearing bolts. Don’t remove them.
(33) Turning the engine over
Turn the engine over, with the cylinder head mounting surface facing down.
NOTE:
Make sure that the cylinder head positioning pins on the cylinder block do not come in contact with the wood block.
(34) Removing the flywheel housing and oil seal case
Remove the flywheel housing and oil seal case from the cylinder black.
80
4. Disassembly and Reassembly
(35) Removing the main bearing.
1) Remove the main bearing bolts.
2) Remove the main bearing cap and lower main bearing metal.
NOTE:
The thrust metal (lower) is mounted to the base main bearing cap.
(36) Removing the crankshaft
1) Remove the crankshaft.
NOTE:
1) The thrust metal (upper) is mounted to the standard main bearing.
2) Remove the main bearing metal (upper) from the cylinder block.
Thrust metal
Crankshaft
Main bearing
(Base)
Main bearing
Main bearing bolt
(Removing main bearing and crankshaft)
(37) Removing the tappets
Remove the tappets from the tappet holes in the cylinder black.
[Precautions when disassembly]
1) Be careful to keep all disassembled parts in order.
2) Clear and adequate area for parts and prepare a container(S).
3) Prepare a cleaner and cleaning can before disassembling start.
81
4. Disassembly and Reassembly
4.3.2 Reassembly
(1) Clean all parts
Clean all parts using by the cloth and diesel oil(or cleaning agent) before reassembly.
NOTE:
1) If the dust remain with the parts, engine may cause the seizing or damage.
2) The cleaning agent removes even carbon adhering to disassembled parts.
(2) Putting the cylinder block upside down
Place a wood block on the floor and put the cylinder block upside down (with the cylinder head mounting surface facing down).
(3) Inserting the tappets
Coat the inside of the cylinder block tappet holes and the outside circumference of the tappets with engine oil, and insert the tappets in the cylinder block.
NOTE:
Separate the tappets to make sure that they are reassembled in the same cylinder No. and intake/ exhaust side as they came from.
(4) Mounting the crankshaft
1) The crankshaft and the crankshaft gear are shrink fitted. If the crankshaft and the crankshaft gear have been disassembled, they have to be shrink fitted [heat the crank shaft gear to 180- 200 deg. C in the hot oil and press fit to the crankshaft].
2) Coat the crank journal part of the cylinder block and the upper main bearing metal with oil and fit the upper main bearing metal onto the cylinder block.
NOTE:
1) Be sure not to confuse the upper and lower main bearing metals. The upper metal has an oil groove.
2) When mounting the thrust metal, fit it so that the surface with the oil groove slit faces outwards, crankshaft side.
3) Coat the crankpins and the crank journals of the crankshaft with engine oil and place it on the upper main bearing metals.
NOTE:
1) Position so that the crankshaft gear is on the gear case side.
2) Be careful not to let the thrust metal drop.
Thrust metal
Crankshaft
Main bearing
(Base)
Main bearing
Main bearing bolt
(Removing main bearing and crankshaft)
82
(5) Mounting the main bearing cap
Coat the lower main bearing metal with engine oil, and mount it to the main bearing cap.
NOTE:
1) The lower main bearing metal does not have an oil hole.
2) The base bearing thrust metal is fitted with the oil groove facing outwards.
1) Coat the flange and the thread of the main bearing bolts with engine oil, put them on the crankshaft journal, and tighten the main bearing bolts to the specified torque.
Tightening torque
Main bearing bolt
N•m(kgf•m)
96-100 (9.8-10.2)
NOTE:
1) The main bearing cap should be mounted with the arrow on the cap pointing towards the flywheel.
2) Make sure to have the correct cylinder alignment number.
2) Measure the crankshaft side clearance.
mm
Crankshaft side clearance
Standard
0.140-0.220
Limit
0.28
3) Make sure that the crankshaft rotates smoothly and easily.
(6) Mounting the oil seal case and the flywheel housing
1) Replace the used oil seal with new one. Press fit the oil seal in the oil seal case, and coat the lip of the oil seal with engine oil
2) Apply the liquid gasket on the mounting surface of the oil seal case and mount the oil seal case to the cylinder block, while matching up with the cylinder block positioning pins.
NOTE:
Be careful that the liquid gasket does not protrude onto the oil pan mounting surface.
3) Mount the flywheel housing to the cylinder block, while matching up with the cylinder block positioning pins.
4. Disassembly and Reassembly
Upper main bearing metal
Oil hole
Lower
Thrust metal
Main bearing cap
F W
Mark
Position number of reassembling
(Main bearing cap)
Groove
Flywheel housing
Parallel pin
Oil seal
Oil seal case
Cylinder block
(7) Turning the engine over
Stand up the engine on the flywheel housing.
83
4. Disassembly and Reassembly
(8) Mounting the gear case flange
Apply the liquid gasket to the gear case flange and mount the gear case flange and lube oil line O-ring onto the cylinder block.
NOTE:
1) When mounting the gear case flange, match up the two knock pins of the cylinder block.
2) Be sure to coat the O-ring for the cylinder block lube oil line with grease when assembling, so that it does not get out of place.
(9) Mounting the piston and connecting rod
1) Reassemble the piston and connecting rod.
NOTE:
1) When reassembling the piston and connecting rod, make sure that the parts are assembled with the correct orientation.
2) Install each piston ring on the piston, with the punched manufacturer’s mark facing upward.
3) The piston ring joints shall be staggered at by
120° intervals. Do not position the top ring joint vertical to the piston pin. The coil expander joint shall be opposite to the oil ring joint.
Make the punched manufacturer's mark face upward.
Second ring joint
(Piston ring)
Oil ring joint
Top ring joint
Expander joint
(Ring joints)
84
4. Disassembly and Reassembly
2) Coat the outside of the piston and the inside of the connecting rod crank pin metal with engine oil and insert the piston with the piston insertion tool.
NOTE:
1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel
2) After inserting the piston, make sure the ID mark on the piston top is located at the fuel nozzle side, looking from the top of the piston.
3) Align the large end match mark, mount the cap, and tighten the connecting rod bolts.
Tightening torque
Connecting rod bolt
N•m(kgf•m)
44.1-49.1(4.5-5.0)
NOTE:
If a torque wrench is not available, match up with the mark made before disassembly.
Piston ID mark
Cylinder size mark
Flywheel side
Piston ID mark
Embossed mark
(Flywheel side)
Match mark
( Assembly direction of connecting rod and piston
)
(10) Mounting the camshaft
1) If the camshaft and the camshaft gear have been disassembled, shrink fit the camshaft and the camshaft gear [heat the camshaft gear to 180-220 deg. C in the hot oil and press fit].
NOTE:
When mounting the camshaft and the camshaft gear, be sure not to forget assembly of the thrust metal. Also make sure they are assembled with the correct orientation.
2) Coat the cylinder block camshaft bearings and camshaft with engine oil, insert the camshaft in the cylinder block, and tighten the thrust metal bolts.
3) Measure the camshaft side gap.
Camshaft gear mm
Thrust metal
Camshaft side gap
Standard
0.05-0.20
Limit
0.30
4) Make sure that the camshaft rotates smoothly.
Side gap
(Camshaft side gap)
85
4. Disassembly and Reassembly
(11) Mounting the idling gear
1) Mount the idling gear so that the oil hole of the idle gear shaft faces up.
NOTE:
The idle gear shaft must be mounted with the mark of the shaft upward.
Mark
Upside
(Idle gear shaft)
2) Align the “A” and “C” match marks of the idle gear with the match marks of the camshaft gear and the crankshaft gear.
3) Measure the idle gear, camshaft gear and crankshaft gear backlash.
mm
Backlash
Standard
0.07-0.15
Limit
0.17
Fuel injection pump drive gear
Camshaft gear
Idle gear
B
B
A
C
C
Seawater pump gear
Crankshaft gear
Direction of rotation
(Gear train)
(12) Mounting the lube oil pump
Mount the lube oil pump to the gear case cover.
Tightening torque
Flush bolt
N•m(kgf•m)
5.4-8.4 (0.55-0.86)
NOTE:
1) Before installing the outer /inner rotors, coat them with lube oil (10W30).
2) Assemble the rotor so that the mark of the rotor may come to the cover side.
3) Confirm that the rotor rotates smoothly.
Lube oil pump cover
Outer rotor
Inner rotor
Gear case
Pressure control valve
Oil seal
(Lube oil pump)
(13) Mounting the gear case cover
1) Replace the used oil seal with new one. Coat the inside and outside of the oil seals with engine oil and press fit it into the gear case cover.
2) Apply the liquid gasket to the gear case cover. Position the two knock pins and tighten the bolts of the gear case cover.
NOTE:
Trim the liquid gasket if it protrudes onto the oil pan mounting surface.
86
4. Disassembly and Reassembly
(14) Mounting the lube oil inlet pipe
Mount the lube oil inlet pipe on the bottom of the cylinder block, using new gasket.
Tightening torque N•m (kgf•m)
Lube oil inlet pipe 26 (2.6)
(15) Mounting the spacer and the oil pan
1) Apply the liquid gasket to the surfaces of the gear case cover, gear case flange and oil seal case on the flywheel housing side, that contact with the cylinder block.
2) Apply the liquid gasket to the spacer. Mount the spacer to the cylinder block and tighten the bolts.
3) Apply the liquid gasket to the oil pan. Mount the oil pan to the spacer and tighten the bolts.
4) Mount the bracket that connects the flywheel housing with the oil pan.
5) Mount the dipstick and dipstick guide.
Cylinder block
977770
-01212
Liquid gasket
Spacer
977770
-01212
Liquid gasket
Oil pan
(16) Mounting the crankshaft V-pulley
1) Coat the oil seal with oil.
2) Make sure to wipe off oil on the taper surface.
3) Tighten to the specified torque.
N•m (kgf•m) Tightening torque
V-pulley bolt
(Materia l: casting iron)
83.2-93.2 (8.48-9.50)
(17) Mounting the engine mounting feet and turning the engine upright.
1) Mount the engine mounting feet.
2) Turn the engine upright(Oil pan is the bottom side).
(18) Mounting the flywheel
1) Coat the flywheel bolts threads with engine oil.
2) Align the positioning pins, and tighten the flywheel bolts to the specified torque.
Tightening torque
Flywheel bolt
N•m (kgf•m)
83.3-88.3 (8.49-9.00)
87
4. Disassembly and Reassembly
(19) Mounting the marine gearbox
1) Mount the fan and damper disk to the flywheel.
2) Align the damper disk with the input shaft spline and insert. Mount the marine gearbox to the flywheel housing.
Damper disk
Marine gearbox
(20) Mounting the cylinder head
1) Put the cylinder head gasket on the cylinder block, aligning it with the cylinder block positioning pins.
2) Lift the cylinder head horizontally and mount it aligning with the cylinder head gasket.
3) Coat the flange part and thread of the cylinder head bolt with engine oil, and lightly tighten the bolts in the specified order. Then tighten completely, in the same order.
Tightening torque
Cylinder head bolt
1st step
39.2-49.1
(4.0-5.0)
N•m (kgf•m)
Final
85.2-91.2
(8.69-9.30)
4) Measure the top clearance mm
Top clearance 0.74±0.06
Assembly
13
7
11
3
Camshaft side
1
6
5 4
10
12
14
9 2 8
Fuel pump side
(Head bolt tightening order)
(21) Mounting the rocker arm shaft assembly and pushrods
1) Fit the pushrod to the tappet.
2) Coat the top of the pushrod and the adjusting screw of the rocker arm with engine oil. Mount the rocker arm shaft assembly to the cylinder head.
(Apply lube oil to the screw and lock nut.)
Tightening torque
Rocker arm shaft support
N•m (kgf•m)
24-27(2.4-2.8)
Valve clearance
Rocker arm Adjusting screw
3) Adjust valve clearance
Intake/exhaust valve clearance 0.15-0.25
mm
4) Coat the rocker arm and valve spring with engine oil and mount the rocker arm cover.
Lock nut
Engine oil
88
4. Disassembly and Reassembly
(22) Mounting the fuel injection pump
1) Lightly fit the fuel injection pump on the gear case flange. (After adjusting injection timing, tighten the fuel injection pump).
NOTE:
Be careful not to scratch the O-ring between the fuel injection pump and gear case flange.
2) Fit the fuel injection pump drive gear to the fuel pump camshaft.
3) Align the “B” match marks on the fuel injection pump drive gear and idle gear.
4) Tighten the pump drive gear nut fastening the fuel pump gear and camshaft to the specified torque.
(Do not apply lube oil to the nut.)
Tightening torque
Pump drive gear nut
N•m (kgf•m )
78.2-98.2 (7.97-10.0)
Idle gear
5) Measure the backlash of the fuel injection pump drive gear.
B
Fuel injection pump drive gear
B
A
C
C
Camshaft gear
Seawater pump gear
Crankshaft gear
Direction of rotation
(Gear train)
Fuel injection pump drive gear 0.07-0.15
(23) Mounting the fuel injection nozzle
1) Replace the used fuel nozzle protector and fuel nozzle seat with new ones. Put the seat in the cylinder head and the protector to the nozzle tip.
Mount the fuel injection nozzle to the cylinder head.
2) Tighten the fuel nozzle retainer bolt to the specified torque. (Do not apply lube oil to the bolt.)
Tightening torque
Fuel nozzle retainer bolt
N•m (kgf•m)
24.4-28.4 (2.49-2.90)
Bolt
Washer
Fuel nozzle retainer
Cylinder head
Fuel injection nozzle
Fuel nozzle protector
Fuel injection seat
(24) Mounting the fresh water pump
1) Thoroughly coat both sides of the gasket with adhesive.
2) Replace the O-ring for the connecting part of the pump, which is inserted in the cylinder block, and tighten the fresh water pump to the specified torque.
Tightening torque N•m (kgf•m)
Fresh water pump 6.9-11 (0.7-1.1)
89
(Fuel injection nozzle)
Cylinder head
Gasket
O-ring
Fresh water pump
4. Disassembly and Reassembly
(25) Mounting the intake manifold
Thoroughly clean the inside of the intake manifold, and mount the gasket packing and intake manifold.
(26) Mounting the fuel injection pipe and fuel return pipe
1) Mount the fuel injection pipe and then assemble the fuel injection pipe retainer to prevent the pipe vibration.
NOTE:
Lightly tighten the pipe joint nuts on both ends of the fuel injection pipe. Completely tighten after adjusting the injection timing.
No.1
No.2
Fuel injection pipe retainer
Standard tightening torque fuel injection pipe joint nut
N•m (kgf•m)
29.4-34.4 (3.00-3.51)
2) Mount the fuel return pipe with the clamp (fuel injection nozzle-fuel filter).
Fuel injection pipe
No.3
Clamp
No.1
No.2
Fuel injection nozzle
No.3
Fuel return pipe
Fuel injection pump
(27) Mounting the lube oil cooler and the lube oil filter.
1) Mount the filter bracket and gasket on the cylinder block.
2) Mount the lube oil cooler to the filter bracket and tighten the lube oil cooler nut.
3) Mount the fresh water pipes (cylinder block-lube oil cooler, lube oil cooler-fresh water pump)
4) Mount the lube oil filter with the tool of the filter case remover.
Cylinder block
Joint
Clamp
Fresh water
Filter bracket
Gasket
To fresh water pump
Drain cock
Clamp
Bolt
Clamp
Lube oil cooler
Lube oil cooler nut
Lube oil filter
(Lube oil filter and cooler)
(28) Mounting the seawater pump
1) Mount the seawater pump assembly and gasket to the gear case.
2) Lightly tap the gear case side bearing rest with a wood hammer, and tighten the bolts.
(29) Mounting the heal exchanger (exhaust manifold, fresh water tank unit).
Mount the gasket and heal exchanger (exhaust manifold).
90
4. Disassembly and Reassembly
(30) Mounting the cooling water pipes (seawater
/ fresh water)
1) Mount the seawater pipes with the hose clips
(seawater pump-heat exchanger).
2) Mount the fresh water pipes with the hose clips
(exhaust manifold – fresh water pump, fresh water pump heat exchanger).
3) Mount the fresh water pipes (cylinder block-lube oil cooler, lube oil cooler-fresh water pump)
Mixing elbow
Heat exchanger
Seawater pump
Seawater inlet
(Seawater pipe)
(31) Mounting the alternator
1) Mount the adjuster on the fresh water pump, the distance piece on the gear case, and then the alternator.
2) Adjust V-belt tension with the adjuster, and tighten the mounting bolts.
(32) Mounting the starting motor
Fit the starting motor in the flywheel housing.
(33) Mounting the mixing elbow
1) Mount ht mixing elbow on the exhaust manifold outlet.
2) Mount the cooing seawater pipe (rubber hose) with the hose clips (heat exchanger-mixing elbow).
(34) Mounting the intake silencer
1) Mount the intake silencer on the intake manifold inlet coupling.
2) Mount the breather hose with the hose clips (intake silencer- rocker arm cover).
(35) Mounting the fuel filter and fuel pipe
1) Mount the fuel filter.
2) Mount the fuel pipe (fuel feed pump-fuel filter, fuel filter-fuel injection pump).
(36) Electrical Wiring
Connect the wiring to the proper terminals, observing the color coding to make sure the connections are correct.
(37) Installation in a boat and completion of the piping and wiring
Mount the engine on the engine bed in the engine room of a boat after all engine assembly has been completed. Connect the cooling water pipes, fuel pipes, other pipes on the boat and the exhaust hoses.
Connect the battery, instrument panel, remote control cable and other wiring.
91
4. Disassembly and Reassembly
(38) Filling with lube oil
Fill the engine with lube oil from the supply port on top of the gear case and fill the marine gearbox from the supply port on top of the clutch case.
(39) Filling with cooling water
1) Open the coolant (fresh water) tank cap and fill with water.
(L)
Engine capacity 4.5
2) Fill with water until the level in the coolant recovery tank is between the full and low marks.
(L)
Coolant recovery tank capacity (full) 0.8
(40) Check fuel injection timing
Refer to 2.2.5(1) in chapter 2.
(41) Test Running
Refer to “Adjusting operation” of 2.4 in chapter 2.
92
5. Inspection and Servicing of Basic Engine Parts
5. Inspection and Servicing of Basic Engine Parts
5.1 Cylinder Block
The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are save shaped to maximize rigidity for strength and low noise.
Cap plug 50 mm
(Camshaft hole) Cap plug 30 mm
Cap plug 30 mm
Cap plug 12 mm
(main gallery)
5.1.1 Inspection of parts
Make a visual inspection to check for cracks on engines that have frozen up, overturned or otherwise been subjected to undue stress. Perform a color check on any portions that appear to be cracked, and replace the cylinder block if the crack is not repairable.
5.1.2 Cleaning of oil holes
Clean all oil holes, making sure that none are clogged up and the blind plugs do not come off.
Color check kit
Penetrant
Developer
Cleaner
Quantity
1
2
3
5.1.3 Color check procedure
(1) Clean the area to be inspected.
(2) Color check kit
The color check test kit consists of an aerosol cleaner, penetrant and developer.
(3) Clean the area to be inspected with the cleaner.
Either spray the cleaner on directly and wipe, or wipe the area with a cloth moistened with cleaner.
(4) Spray on red penetrant
After cleaning, spray on the red penetrant and allow 5-10 minutes for penetration. Spray on more red penetrant if it dries before it has been able to penetrate.
(5) Spray on developer
Remove any residual penetrant on the surface after the penetrant has penetrated, and spray on the surface after the penetrant has penetrated, and spray on the developer. If there are any cracks in the surface, red dots or a red line will appear several minutes after the developer dries.
Hold the developer 300-400mm away from the area the surface uniformly.
93
5. Inspection and Servicing of Basic Engine Parts
(6) Clean the surface with the cleaner.
NOTE: Without fail, read the instructions for the color check kit before use.
5.1.4 Replacement of cup plugs
Step
No.
Description
1 Clean and remove grease from the hole into which the cup plug is to be driven.
(Remove scale and sealing material previously applied.)
Procedure
Remove foreign materials with a screw driver or saw blade.
Tool of material used
Screw driver or saw blade
Thinner
2 Remove grease from the cup plug.
Visually check the nick around the plug.
Thinner
3
4
Apply Threebond No.4 to the seat surface where the plug is to be driven in.
Insert the plug into the hole.
Apply over the whole outside of the plug.
Insert the plug so that it sits correctly.
Threebond No.4
5 Place a driving tool on the cup plug and drive it in using a hammer.
Drive in the plug parallel to the seating surface.
• Driving tool
• Hammer
2 3 mm
*Using the special tool, drive the cup plug so that the edge of the plug is 2mm (0.0787in) below the cylinder surface.
3 mm
Plug dia.
12
30
50
100 mm d
19.9-12.0
29.9-30.0
49.5-50.0
D
20
40
60 mm
94
5. Inspection and Servicing of Basic Engine Parts
5.1.5
Cylinder bore
measurement
Especially clean head surface, cylinder bores and oil holes, and check the below items after removing any carbon deposit and bonding agent.
(a) Appearance inspection
Check if there is any discoloration or crack. If crack is suspected, perform color check. Sufficiently clean the oil holes and check they are not clogged.
(b) Cylinder bore and distortion
Measure at 20 mm below the crest of the liner, at 20 mm from the bottom end and at the center in two directions A and B as shown in the below figure.
Roundness:
Roundness is found as follows though it is the simple method.　Measure cylinder diameters of the
A direction and the B direction on each section of a, b and c.
Roundness is the maximum value among those difference values.
Cylindricity:
Cylindricity is found as follows though it is the simple method.
Measure cylinder diameters of a, b and c sections in the A direction, and calculate the difference in maximum value and minimum value of the measured diameters.
In the same way measure and calculate the difference in the B direction.
Cylindricity is the maximum value between those difference values.
mm
Standard
Cylinder bore dia.
88.000-88.030
Cylinder roundness/
Inclination
0.01 or less
Limit
88.200
0.03
a
(Cylinder bore)
20 mm
A b c
B
Measure in two directions
A and B at points a, b and c.
20 mm
(Cylinder bore measurement positions)
95
5. Inspection and Servicing of Basic Engine Parts
5.2 Cylinder Head
The cylinder head is of 3-cylinder integral construction, mounted with 14 bolts. Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet.
Rocker arm support
Rocker arm cover
Rocker arm
Rocker arm spring
Rocker arm shaft
Valve cap
Cotter
Spring retainer
Valve spring
Stem seal
Valve guide
Cylinder head
Exhaust valve
Suction valve
(2-Valve cylinder head)
96
5. Inspection and Servicing of Basic Engine Parts
5.2.1 Inspecting the cylinder head
The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts.
(1) Distortion of the combustion surface
Carefully check for cylinder head distortion as this leads to gasket damage and compression leaks.
1) Clean the cylinder head surface.
2) Place a straight-edge along each of the four sides and each diagonal. Measure the clearance between the straight- edge and combustion surface with a feeler gauge.
Standard Wear limit mm
Cylinder head distortion
0.05 or less 0.15
Straight-edge
Thickness gage
(Distortion at combustion surface)
(2) Checking for cracks in the combustion surface
Remove the fuel injection nozzle, intake and exhaust valve and clean the combustion surface. Check for discoloration or distortion and conduct a color check test to check for any cracks.
(3) Checking the intake and exhaust valve seats
Check the surface and width of the valve seats.
If they are too wide, or if the surfaces are rough, correct to the following standards:
Seat angle
Intake
Exhaust
120°
90°
Seat width
Intake
Exhaust
Standard
1.07-1.24
1.24-1.45
Limit
1.74
1.94
97
5. Inspection and Servicing of Basic Engine Parts
5.2.2 Valve seat correction procedure
The most common method for correcting unevenness of the seat surface with a seat grinder is as follows:
(1) Use a seat grinder to make the surface even.
As the valve seat width will be enlarged, first use a 70 ° grinder, then grind the seat to the standard dimension with a 15 ° grinder.
NOTE:
When seat adjustment is necessary, be sure to check the valve and valve guide. If the clearance exceeds the tolerance, replace the valve or the valve guide, and then grind the seat.
Seat grinder
Seat
(2) Knead valve compound with oil and finish the valve seat with a lapping tool.
(3) Final finishing should be done with oil only.
Lapping tool
Use a rubber cap type lapping tool for cylinders without a lapping tool groove with oil only.
NOTE:
Clean the valve and cylinder head with light oil or the equivalent after valve seat finishing is completed and make sure that there are no grindings remaining.
NOTE:
1) Insert adjusting shims between the valve spring and cylinder head when seats have been refinishing with a seat grinder.
2) Measure valve distortion after valve seat refinishing has been completed, and replace the valve and valve seat if it exceeds the tolerance.
(Valve lapping tool)
Seat width
98
5. Inspection and Servicing of Basic Engine Parts
5.2.3 Intake/exhaust valves, valve guides
(1) Wearing and corrosion of valve stem
Replace the valve stem is excessively worn or corroded.
mm
Valve stem outside dia.
Intake
Exhaust
Standard
Ø7.955-Ø7.975
Ø7.955-Ø7.970
Limit
Ø7.90
Ø7.90
30 mm 60 mm
(2) Inspection of valve seat wear and contact surface
Inspect for valve seat scratches and excessive wear. Check to make sure the contact surface is normal.
The seat angle must be checked and adjusted if the valve seat contact surface is much smaller than the width of the valve seat.
NOTE:
Keep in mind the fact that the intake and discharge valve have different diameters.
(3) Valve sink
Over long periods of use and repeated lapping, combustion efficiency may drop. Measure the sinking distance and replace the valve and valve seat if the valve sink exceeds the tolerance.
mm
Valve sink
Standard
0.30-0.50
Limit
0.8
Valve sinking depth
(Valve sink depth)
Depth micrometer
(Valve sink)
99
5. Inspection and Servicing of Basic Engine Parts
(4) Valve guide
1) Measuring inside diameter of valve guide.
Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit.
mm
Valve guide inside dia.
Clearance
Intake
Exhaust
Intake
Exhaust
Standard
Ø8.010-Ø8.025
Ø8.015-Ø8.030
0.035-0.070
0.045-0.075
Limit
Ø8.2
Ø8.2
0.18
0.18
NOTE: The inside diameter standard dimensions assume a pressure fit.
2) Replacing the valve guide
Use the insertion tool and tap in the guide with a mallet.
The intake valve guide and exhaust valve guide are of different dimensions.
Tool
Valve guide
Cylinder head
Tool
Valve guide
3) Valve guide projection
The valve guide should project 15mm from the top of the cylinder head.
4) Valve stem seals
The valve stem seals in the intake/exhaust valve guides cannot be re-used once they are removed
- be sure to replace them.
When assembling the intake/exhaust valves, apply an adequate quantity of engine oil on the valve stem before inserting them.
Exhaust stem seal is marked by yellow. Intake stem seal is not marked.
Projection
0 -0.3
0 -0.3
Stem seal
Valve guide
100
5.2.4 Valve springs
(1) Checking valve springs
1) Check the spring for scratches or corrosion.
2) Measure the free length of the spring.
5. Inspection and Servicing of Basic Engine Parts
Free length
3) Measure inclination.
Square gauge
B
A
(Valve spring)
Inclination
(Valve spring)
4) Measure spring tension.
Valve spring
Free length A
Inclination B
Tension
(1mm pressure)
(Smaller pitch/
Larger pitch)
Unit mm mm
N/mm
(kgf/mm)
Standard
44.4
–
26.6/35.4
(2.71/3.61)
Limit
43.0
1.1
–
5) Assembling valve springs.
The side with the smaller pitch (painted yellow) should face down (cylinder head).
Up side
Spring tension tester
Smaller pitch side (yellow)
Down side
NOTE:
The pitch of the valve spring is not even. The side with the smaller pitch (yellow) should face down
(cylinder head) when assembled.
101
5. Inspection and Servicing of Basic Engine Parts
6) Spring retainer and spring cotter
Inspect the inside face of the spring retainer, the outside surface of the spring cotter, the contact area of the spring cotter inside surface and the notch in the head of the valve stem. Replace the spring retainer and spring cotter when the contact area is less than 70%, or when the spring cotter has been recessed because of wear.
5.2.5 Assembling the cylinder head
Partially tighten the bolts in the specified order and then tighten to the specified torque, being careful that the head does not get distorted.
(1) Clean out the cylinder head bolt holes.
(2) Check for foreign matter on the cylinder head surface where it comes in contact with the block.
(3) Coat the head bolt threads and nut seats with lube oil.
(4) Use the positioning pins to line up the head gasket with the cylinder block.
(5) Match up the cylinder head with the head gasket and mount.
Cylinder head bolt tightening torque
First
44-54
(4.5-5.5)
N•m (kgf•m)
Second
85.2-91.2
(8.69-9.30)
Disassembly
2
8
12
Camshaft side
14
9
5
3
4 10 11 1
6 13 7
Assembly
Head bolt disassembly order
(3 cylinder head)
Camshaft side
13
7
3
1
6
10
12
11
9
5 4
2 8
Head bolt tightening order
(3 cylinder head)
14
5.2.6 Measuring top clearance
(1) Place a high quality fuse ( Ø 1.5mm, 10mm long) in three positions on the flat part of the piston head.
(2) Assemble the cylinder head gasket and the cylinder block and tighten the bolts in the specified order to the specified torque.
(3) Turn the crank, (in the direction of engine revolution), and press the fuse against the piston until it breaks.
(4) Remove the head and take out the broke fuse.
Fuse wire
(5) Measure the three positions where each fuse is broken and calculate the average.
mm
Top clearance 0.68-0.80
102
5. Inspection and Servicing of Basic Engine Parts
5.2.7 Intake and exhaust rocker arms
The wear of rocker arm and rocker arm bushing may change opening/closing timing of the valve, and may in turn affect the engine performance according to the extent of the change.
(1) Rocker arm shaft and rocker arm bushing
Measure the outer diameter of the shaft and the innerdiameter of the veering, and replace if wear exceeds the limit.
Standard mm
Limit
(Rocker arm hole diameter)
Outside dia of intake and exhaust rocker arm shaft.
Intake and exhaust rocker arm bushing inside dia.
Rocker arm shaft and bushing clearance at assembly
15.966-15.984
15.955
16.000-16.020
16.090
0.016-0.054
0.140
Replace the rocker arm bushing if it moves and replace the entire rocker arm if there is no tightening clearance.
(2) Rocker arm spring
Check the rocker arm spring and replace it if it is corroded or worn.
(3) Rocker arm and valve cap wear
(4) Inspect the contact surface of the rocker arm and replace it if there is abnormal wear or flaking.
5.2.8 Adjustment of valve clearance
(1) Make adjustments when the engine is cool.
(Refer to 2.2.2(5).)
Intake and exhaust valve clearance 0.15-0.25
mm
(2) Be sure that the opening and closing angles for both the intake and the exhaust valves are checked when the timing gear is disassembled (The gauge on the flywheel can be read.).
Intake valve Open
Intake valve Closed
Exhaust valve Open
Exhaust valve Closed b.TDC.
a.BDC.
b.BDC.
a.TDC.
deg.
10°-20°
40°-50°
51°-61°
13°-23°
Exhaust 254
10
40
T.D.C.
20
13
23
61
Intake 281
50
51
B.D.C.
103
5. Inspection and Servicing of Basic Engine Parts
5.3 Piston and Piston Pins
Pistons are made of a special light alloy with superior thermal expansion characteristics, and the top of the piston forms a swirl type toroidal combustion chamber.
IMPORTANT:
Piston shape differs among engine models. If any incorrect piston is installed, combustion performance will drop. Be sure to check the applicable engine model identification mark “V88” on the piston for
3JH4E series to insure use of the correct part.
ID marks for piston
ML
MS
1st compression ring
2st compression ring
Oil ring
I.D. mark
Piston
Piston pin
5.3.1 Piston
Circlip
(1) Piston head and combustion surface
Remove the carbon that has accumulated on the piston head and combustion surface, taking care not to scratch the piston. Check the combustion surface for any damage.
(2) Measurement of piston outside diameter/ inspection
1) Replace the piston if the outsides of the piston or ring grooves are worn.
2) Measure the outside diameter in the position of
22mm from the piston bottom in the right angle direction of the piston pin.
Piston outside diameter
Standard Limit
87.950-87.960
87.900
Clearance between piston and cylinder
0.045-0.075
Measurement position
22 mm
(Piston outside diameter)
If the piston outside diameter exceed the limit, replace the piston with new one.
Selective pairing of cylinder and piston
Piston must be paired with cylinder according to the below table. The size mark of a piston is shown on the top surface of the piston and the size mark of a cylinder block is shown on the non-operating side of the cylinder block. The service parts of pistons are provided.
Tolerance
Size mark
Piston outside diameter.
D2=87.955 mm below+0.005
0 min.
below 0
-0.005 min.
ML MS
Cylinder inside diameter
D1=88.000 mm
+0.030 max.
+0.020 min.
below +0.020
+0.010 min.
below +0.010
0 min.
L
M
S
{
{
X
X
{
{
104
5. Inspection and Servicing of Basic Engine Parts
(3) Removing the piston pin
A floating type piston pin is used in this engine. The piston pin can be pressed into the piston pin hole at room temperature (Coat with oil to make it slide easily).
5.3.2 Piston pin
Measure the outer diameter and replace the pin if it is excessively worn.
Standard Limit
Piston pin hole inside dia.
Piston pin outside dia.
Clearance
Ø26.000-26.009
Ø25.995-26.000
0-0.014
Ø26.020
Ø25.965
0.074
Measure at positions a and b in directions A and B.
a b
B
A
(Piston pin hole)
Measure at positions a, b and c in directions A and B.
a b
A c
B
(Piston pin outside diameter)
5.3.3 Piston rings
There are 2 compression rings and 1 oil ring.
The absence of an oil ring on the piston skirt prevents oil from being kept on the thrust surface and in turn provides good lubrication
Top ring
Second ring
Oil ring
(Ring components)
105
5. Inspection and Servicing of Basic Engine Parts
(1) Measuring the rings.
Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit.
First piston ring
Second piston ring
Oil ring
Standard
Groove width 2.060-2.075
Ring width 1.970-1.990
Clearance 0.070-0.105
Groove width 2.025-2.040
Ring width
Clearance
1.970-1.990
0.035-0.070
Groove width 4.015-4.030
Ring width 3.970-3.990
Clearance 0.025-0.060
Limit
2.170
1.950
0.200
2.140
1.950
0.190
4.130
3.950
0.180
mm
(2) Measuring piston ring gap (End clearance)
Press the piston ring onto a piston liner and measure the piston ring gap with a gauge. Press on the ring about 30mm from the bottom of the liner.
mm
Standard Limit
First piston ring gap
Second piston ring gap
Oil ring gap
0.200-0.400
0.200-0.400
0.200-0.400
0.490
0.490
0.490
Width
Thickness
(Measuring side clearance)
Head surface
Cylinder block
Piston ring
Approx.
30 mm
Gap
(3) Removing the piston rings
1) Thoroughly clean the ring grooves when removing piston rings.
2) The side with the manufacturer’s mark should face up.
Make the punched manufacturer's mark face upward.
(Piston ring)
106
5. Inspection and Servicing of Basic Engine Parts
3) After fitting the piston ring, make sure it moves easily and smoothly.
4) Stagger the piston rings at 120° intervals, making sure none of them line up with the piston.
1st piston ring
120
Direction of piston pin
Oil ring
2nd piston ring
120
1st piston ring
2st piston ring
Oil ring
2st piston ring
120
120
1st piston ring
120
Oil ring
5) The oil ring is provided with a coil expander. The coil expander joint should be opposite (staggered
180°) the oil ring gap.
Gap
Joint of coil expander
107
5. Inspection and Servicing of Basic Engine Parts
5.4 Connecting Rod
The connecting rod is made of high-strength forged carbon steel.
The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing.
Connecting rod
Piston pin bushing
Crank pin metal
Connecting rod
(bid end cap)
Connecting rod bolt
5.4.1 Inspecting the connection rod
(1) Twist and parallelism of the large and small ends
Insert the measuring tool into the large and small ends of the connecting rod. Measure the extent of twist and parallelism and replace if they exceed the tolerance.
mm
Standard Limit
Connecting rod twist and parallelism
Less than 0.03
(at 100 mm)
0.08
100 mm
100 mm
Parallelism
Twist
Mandrel
(Twist and parallelism measurement)
108
Connecting rod aligner
( Twist measurement using ) a connecting rod aligner
5. Inspection and Servicing of Basic Engine Parts
(2) Checking the side clearance of a connecting rod
Fit the respective crank pins to the connecting rod and check to make sure that the side clearance in the crankshaft direction is correct.
Standard Limit
Connecting rod side clearance
0.20-0.40
0.55
Crankshaft
Thickness gage
(Connecting rod side gap)
5.4.2 Crank pin metal
(1) Checking crank pin metal
Check for flaking, melting or seizure on the contact surface of the crank pin metal.
(2) Measuring crank pin oil clearance
Measure the crankpin outside diameter and the crank pin metal inside diameter. Calculate the oil clearance from the measured values.
(Refer to 5.5.1(3) for measuring the crank pin outside diameter.)
Replace the crank pin metal if the oil clearance becomes about the limit dimension of the below table.
Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Also use an undersized metal if necessary.
[NOTICE]
When measuring the inside diameter of the rod big end, install the crank pin metal in the rod big end not to mistake the top and bottom of the metals and tighten the rod bolts by the standard torque.
Rod bolt tightening torque
N•m(kgf•m)
44.1-49.1
(4.50-5.01) mm
Cylinder gage
(Rod bushing I.D. measurement)
Item
Rod metal I.D.
Crankpin O.D.
Metal thickness
Clearance
Standard
48.000-48.026
47.952-47.962
1.492-1.500
0.038-0.074
Limit
-
47.902
-
0.150
109
5. Inspection and Servicing of Basic Engine Parts
• Other procedure of measuring crank pin oil clearance
1) Use the press gauge (Plastic gauge) for measuring the oil clearance of the crank pin.
2) Mount the connecting rod on the crank pin (tighten to specified torque).
3) Remove the connecting rod and measure the broken plastic gauge with measuring paper.
Plastic gauge
(3) Precautions on replacement of crank pin metal
1) Wash the crank pin metal.
2) Wash the large end cap, mount the crank pin metal and make sure that it fits tightly on the large end cap.
3) When assembling the connecting rod, match up the large end and large end cap number. Coat the bolts with engine oil and gradually tighten them alternately to the specified torque.
If a torque wrench is not available, make match marks on the bolt heads and large end cap before disassembling (to indicate the proper torque position) and retighten the bolts to those positions.
4) Make sure there is no sand, metal cuttings or other foreign matter in the lube oil, and that the crankshaft is not scratched. Take special care in cleaning the oil holes.
Alignment mark (Punched mark)
Matching mark
110
5. Inspection and Servicing of Basic Engine Parts
5.4.3 Piston pin bushing
(1) Measuring piston pin clearance.
Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself.
Measure the piston pin bushing inside diameter and the piston pin outside diameter. Calculate the oil clearance from the measured values. (Refer to 5.3.2
for the piston pin.) mm
Standard Limit
Piston pin bushing inside dia
Oil clearance
26.025-26.038
0.025-0.043
26.068
0.101
NOTE:
Since the rod small end is tapered, bush insertion is extremely difficult. Any minor mistake will cause abnormalities such as twist and bite. Do not insert the bush on-site.
(No piston pin bush spare part is available. It is included in the connecting rod assembly supplied as a spare part.)
5.4.4 Assembling piston and connecting rod
The piston and connecting rod should be assembled so that the match mark on the connecting rod large en faced the fuel injection pump side and the combustion chamber above the piston is close to the fuel injection pump.
Cylinder gage
(Connecting rod small end)
Piston ID mark
Cylinder size mark
Flywheel side
Piston ID mark
Embossed mark
(Flywheel side)
Match mark
( Assembly direction of connecting rod and piston
)
111
5. Inspection and Servicing of Basic Engine Parts
5.5 Crankshaft and Main Bearing
The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is provided with for balance weights for optional balance.
The crankshaft main veering is of the hanger type. The upper metal (cylinder block side) is provided with an oil groove. There is no oil groove on the lower metal
(bearing cap side). The veering cap (location cap) of the flywheel side has a thrust metal which supports the thrust load.
Main bearing metal (basic)
Thrust metal
Main bearing cap (basic)
Main bearing bolt
Balance weight
Crank shaft
Crank shaft gear
Main bearing metal
(intermediate)
Main bearing cap
(intermediate)
Main bearing bolt
5.5.1 Crankshaft
(1) Color check after cleaning the crankshaft, and replace the crank shaft if there is any cracking or considerable damage.
(Inspection by color check)
(2) Bending of the crankshaft
Support the crankshaft with V-blocks at both ends of the journals. Measure the deflection of the center journal with a dial gauge while rotating the crankshaft to check the extent of crankshaft bending.
mm
Crankshaft bend limit 0.02
Bend
Deflection
Dial gage
V-block V-block
(Crankshaft bend measurement)
112
5. Inspection and Servicing of Basic Engine Parts
(3) Measuring the crank pin and journal
Measure the outside diameter, roundness and taper at each crank pin and journal.
Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive.
mm
Roundness
Taper
Item Limit (Diameter)
0.01
To look for the oil clearance of crank pin, measure the inside diameter of crank pin metal. (Refer to 5.4.2(2). )
Crank pin
Outside dia.
Oil clearance
Outside dia.
Standard
Ø47.952-
47.962
0.038-
0.074
Ø49.952-
49.962
0.038-
0.068
Limit mm
47.902
0.150
49.902
Crank journal
Oil clearance
0.150
• Dimension R and finishing precision of crankshaft journal and pin
As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension R of below table.
Surface finishing precision standard on journal and pin:
Ry=0.8S super polishing
Surface finishing precision standard on the thrust side of crankshaft arm:
Crankshaft journal
Crank pin
( Measuring position of the crank pin ) and crank journal
R
R
Super polishing
Ry=0.8S
Crank Pin
R
R
Super polishing
Ry=0.8S
Thrust face
R
Crank Journal
(Crankshaft R machining)
Finishing precision standard of dimension R (mm)
3.5+0.3/0
NOTICE:
1) lf the oil clearance is excessive though the thickness of the journal and crankpin metals are normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
2) lf rust or surface roughening exists on the rear side of the metals, coat it with blue or minimum.
Then assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to check the metal for contact. lf the contact surface occupies 75% or more, the metal is normal. lf the contact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.
113
5. Inspection and Servicing of Basic Engine Parts
(4) Checking the side gap of a crankshaft
After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance.
Replace the thrust bearing if it is worn beyond the limit.
Crankshaft side gap
Standard
0.14-0.22
Limit
0.30
mm
Other measurement method can also be effective.
Insert the thickness gauge directly into the clearance between the thrust metal and crankshaft thrust face.
(Side gap measurement 1)
Standard width
Thrust face
Cylinder block
Crankshaft
Thrust metal
Bearing cap
Thickness gauge
(Side gap measurement 2)
114
5. Inspection and Servicing of Basic Engine Parts
5.5.2 Main bearing
(1) Inspecting the main bearing
Check for flaking, seizure or burning of the contact surface and replace if necessary.
(2) Measuring the inner diameter of metal
Tighten the cap to the specified torque and measure the inner diameter of the metal.
Block side main bearing metals
Cap side main bearing metals
Thrust metals
Main bearing bolt
(Main bearing) mm
Crank journal
(Selective pairing)
Inspection item
Journal outside diameter
Metal inside diameter
Metal thickness
Clearance
Standard
49.952-49.962
51.000-51.010
1.995-2.010
0.038-0.068
Tightening torque
N•m(kgf•m)
96-100 (9.8-10.2)
NOTE:
When assembling the bearing cap, keep the following in mind.
1) The lower metal (cap side) has no oil groove.
2) The upper metal (block side) has an oil groove.
3) Check the cylinder block alignment number.
4) The “FW” on the cap lies on the flywheel side.
Limit
49.902
-
-
0.150
115
5. Inspection and Servicing of Basic Engine Parts
5.6 Camshaft and Tappets
5.6.1 Camshaft
The camshaft is normalized and the cam and bearing surfaces are surface hardened and ground. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life.
Push rod
Tappet
Camshaft
Camshaft bushing
Camshaft gear
Thrust metal
Camshaft gear
Thrust metal
(1) Checking the camshaft side gap
The load is received the standard veering near the end of the camshaft by the cam gear, resulting in rapid wear of the en of the veering and enlargement of the side gap. Therefore, measure the thrust gap before disassembly As the cam gear is shrink-fitted to the cam, be careful when replacing the thrust bearing.
mm
Camshaft side gap
Standard
0.05-0.20
Limit
0.35
(2) Measure the cam height, and replace the cam if it is worn beyond the limit.
Standard mm
Limit
Cam height
Intake
Exhaust
38.600-38.800
38.350
Side gap
(Camshaft side gap)
Cam height
Micrometer
(Cam height)
116
5. Inspection and Servicing of Basic Engine Parts
(3) Camshaft and bearing hole measurement
Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the inside diameter of the camshaft bearing or bushing. The camshaft bushing at gear case side is measured with a cylinder gage after insertion to the cylinder.
Replace if they exceed the limit or are damaged.
Flywheel side
Place Item Standard mm
Limit
Bushing I.D. 44.990-45.055
45.130
Gear side
Camshaft
O.D.
Oil clearance
44.925-44.950
0.040-0.130
44.890
0.240
Intermediate position
Bushing I.D. 45.000-45.025
45.100
Camshaft
O.D.
44.910-44.935
44.875
Oil clearance
0.065-0.115
0.225
Bushing I.D. 45.000-45.025
45.100
Camshaft
O.D.
Oil clearance
44.925-44.950
0.050-0.100
44.890
0.210
(4) Bending of the camshaft
Support both ends of the camshaft with V-blocks, place a dial gauge at the central bearing areas and measure bending. Replace if excessive.
NOTE:
The reading on the dial gauge is divided by two to obtain the camshaft bend.
mm
Camshaft bend
Standard
0.02 or less
Limit
0.05
Flywheel side
(Camshaft outside diameter)
V-block
Micrometer
Dial gage
(Camshaft bend)
117
5. Inspection and Servicing of Basic Engine Parts
5.6.2 Tappets
(1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of each tappet and replace if excessively or unevenly worn.
NOTE:
When removing tappets, be sure to keep them separate for each cylinder and intake/exhaust valve.
Abnormal contact surface
Normal contact surface
(Tappet)
(2) Measure the outer diameter of the tappet, and replace if worn beyond the limit.
mm
Standard Limit
Tappet stem outside dia.
Tappet guide hole inside dia.
(cylinder block)
Oil clearance
11.975-11.990
12.000-12.018
0.010-0.043
11.930
12.045
0.090
(Tappet stem outside diameter measurement)
(3) Measuring push rods.
Measure the length and bending of the push rods.
mm
Push rod length
Push rod bend
Push rod dia.
Standard
178.25-178.75
Less than 0.03
8.5
Limit
-
0.03
-
Thickness gage
(Push rod bend)
118
5. Inspection and Servicing of Basic Engine Parts
5.7 Timing Gear
The timing gear is helical type for minimum noise and specially treated for high durability.
5.7.1 Inspecting the gears
(1) Inspect the gears and replace if the teeth are damaged or worn.
(2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.
NOTE:
If backlash is excessive, it will not only result in excessive noise and gear damage, but also lead to bad valve and fuel injection timing and a decrease in engine performance.
mm
Backlash
Standard
0.07-0.15
Limit
0.17
(3) Idling gear
The bushing is pressure fitted into the idling gear.
Measure the bushing inner diameter and the outer diameter of the shaft, and replace the bushing or idling gear shaft if the oil clearance exceeds the wear limit.
A,B and C are inscribed on the end of the idling gear.
When assembling, these marks should align with those on the cylinder block.
mm
Standard Limit
Idle gear shaft dia.
Idle gear bushing inside dia.
Oil clearance
45.950-45.975
46.000-46.025
0.025-0.075
45.880
46.075
0.15
Idle gear
Idle gear bushing
Idle gear shaft
5.7.2 Gear timing marks
Match up the timing marks on each gear when assembling (A,B and C).
Fuel injection pump drive gear
Camshaft gear
Idle gear
B
B
A
C
C
Seawater pump gear
Crankshaft gear
Direction of rotation
(Gear train)
119
5. Inspection and Servicing of Basic Engine Parts
5.8 Flywheel and Housing
The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.
The flywheel is mounted and secured by 6 bolts on the crankshaft end at the opposite end to the gear case; it is covered by the mounting flange (flywheel housing) which is bolted to the cylinder block.
the fitting surface for the damper disc is on the crankshaft side of the flywheel. The rotation of the crankshaft is transmitted through this disc to the input shaft of the reduction and reversing gear. The reduction and reversing gear is fitted to the mounting flange.
The flywheel’s unbalanced force on the shaft center must be kept below the specified value for the crankshaft as the flywheel rotates with the crankshaft at high speed.
To achieve this, the valance is adjusted by drilling holes in the side of the flywheel, and the unbalanced momentum is adjusted by drilling holes in the circumference.
The ring gear is shrink fitted onto the circumference of the flywheel, and this ring gear serves to start the engine by meshing with the starter motor pinion.
The stamped letter and line which show top dead center of each cylinder are positioned on the flywheel circumference, and by matching these marks with the arrow mark at the hole of the flywheel housing, the rotary position of the crankshaft can be ascertained in order to adjust tappet clearance or fuel injection timing.
5.8.1 Position of top dead center and fuel injection timing
(1) Marking
Flywheel housing
Injection timing marks
No.1 cylinder
T.D.C.
Flywheel
Hole
(2) Matching mark
The matching mark is made at the hole of the flywheel housing.
Flywheel housing
1
Matching mark
Hole
120
5.8.2 Damper disc and cooling fan
Cooling fan
5. Inspection and Servicing of Basic Engine Parts
Damper disc
Flywheel
6- 8.70 8.92
16
Flywheel side mm
Torsional rigidity
Max. angle of torsion
Stopper torque
219 kgf•m/rad
7.3 x 10 -2 rad
20.8 kgf•m
121
2
19.5
6
7.1
6. FUEL INJECTION EQUIPMENT
6. FUEL INJECTION EQUIPMENT
6.1 Fuel Injection Pump/Governor
Refer to the JH3E manual of separate volume for the disassembly and assembly, adjustment procedure of a fuel injection pump.
6.1.1 Fuel system diagram
Fuel nozzle
Fuel injection pipe
Fuel injection pump
Fuel return pipe
Fuel filter
To fuel tank
Feed pump
Water separator
From fuel tank
122
6. FUEL INJECTION EQUIPMENT
6.1.2 Fuel injection pump service data
(1) 3JH4(B)(C)E
Part code (Back No.)
Adjustment SPEC
Item Fuel valve (Valve pressure)
Nozzle type (ID mark)
Injection
Adjustment
Fuel injection pipe
Starting Pump speed
Ns
Average injection volume Qs
Rated load Pump speed
No
Injection volume Qo
Nonunifomity
Torque rise Pump speed
N
T
Injection volume Q
T
Nonunifomity
Hi-idle Pump speed
N
Hi
Idle
Injection volume Q
Hi
Pump speed
Ni
Qi
Nonunifomity
Plunger stroke
Plunger dia.
Suction volume of delivery valve
Pre-stroke
Top clearance
Governor spring
Spring constant
Free length
-
-
-
mm min -1 mm
3
/st min -1 mm
3
/st
% min -1 mm 3 /st
% min -1 mm 3 /st min -1 mm
3
/st
% mm mm mm
3 mm mm
N/cm
(kgf/cm) mm
729271-51450 (TM02)
ENG SPEC SERVICE STD
VBG(220)
159P185VAD1
Ø 1.6 x 360
(170)
DN-12SD12
Ø2 x 600
200 -
45 ± 5.0
-
1500
32.5 ± 0.75
± 3
-
-
-
1660 + 15 / -10
6 - 7
400
9 - 10
± 10
8.0
8
36
3.0
0.5
2.76 (0.281)
41
-
-
-
-
-
-
-
-
-
-
-
123
6. FUEL INJECTION EQUIPMENT
(2) Adjusting fuel limit bolt at rated load
1) Adjust the fuel limit bolt to bring the rack position to the specified value (R
0
) with the governor control lever towards the fuel increase position, while keeping the pump at rated speed N
0
.
2) Measure fuel injection volume at rack position
(R
0
).
3) If the injection volume is at the specified value, tighten the fuel limit bolt lock nut at that position.
Note : The figure in the blank ( ) is the indicator.
At starting
R
S
19
(12)
0.5
R 0
15
(8)
R 3
R 2
7
(0)
N
S
Ni N
O
N Hi
Pump rpm N (rpm)
(3) Adjusting fuel limit bolt at starting
1) Adjust the fuel limit bolt at starting to bring the rack position to the specified value (Rs), while keeping the pump at starting speed Ns.
2) Measure fuel injection volume at starting position
(Rs).
3) If the injection volume is at the specified value, tighten the fuel limit bolt lock nut at that position.
Fuel limit bolt at starting
124
6.1.3 Fuel injection pump structure
(1) Component
Plunger spring
Control rack
Tappet
6. FUEL INJECTION EQUIPMENT
Delivery valve
Barrel
Plunger
Camshaft
Fuel injection pump
Governor
Feed pump
Don't disassemble!
Pump flange
Fuel pump drive gear
Pump flange bolts
Drive gear nut
Pump flange bolt
125
6. FUEL INJECTION EQUIPMENT
(2) Section of a fuel injection pump/ governor for 3JH4(B)(C)E
126
6. FUEL INJECTION EQUIPMENT
6.1.4 Removing a fuel injection pump
The procedure to remove a fuel injection pump from the gear case is shown.
[NOTICE]
Be sure to remove a flange and a fuel injection pump drive gear as a pair without loosening the flange bolts.
Fuel injection pump
1) Remove fuel injection pipes, fuel pipes and a remote control wire. Block the entrance with tape so that trash may not enter the fuel injection pipes and the fuel injection pump.
2) Mark the position of the timing marks of a fuel pump and a gear case. Or, put a mark on the gear case at the position to agree the timing mark of a fuel pump.
3) Remove a pump cover from the gear case.
4) Give the marks on a fuel injection pump drive gear and a idle gear with paint or the like.
5) Loosen fuel injection pump installation nuts (three nuts).
Don't disassemble
Flange
Fuel injection drive gear
6) Loosen a installation nut of a fuel injection pump drive gear.
7) Pull a fuel injection pump drive gear and a flange with a pair to your side by gear puller.
8) Remove a pump drive gear nut and a washer.
9) Remove a fuel injection pump. Leave the pump drive gear in the gear case.
Flange bolt
Pump drive gear nut
Spring washer
6.1.5 Installing a fuel injection pump
[NOTICE]
• Use a new O-ring on the fuel pump flange and apply grease.
• Confirm whether the marks of the pump drive gear and the idle gear is correct.
1) Turn a camshaft so that the key of the pump camshaft may almost agree in a position of the key groove of a pump drive gear.
2) Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the O-ring. Insert a fuel pump while confirming whether the key of a camshaft and the key groove of a drive gear agree.
3) Assemble a pump drive gear nut and a washer together temporarily.
4) Turn a fuel injection pump to the position where the marks of the fuel injection pump and the gear case agrees.
5) Fasten pump installation nuts (three nuts) on the fuel injection pump.
6) Tighten the pump installation nut by the specified standard torque.
Tightening torque of the pump drive gear nut (without lube oil)
Tightening torque
78-88 (8-9)
N•m(kgf•m)
6.1.6 Adjusting fuel injection timing
Refer to 2.2.5(1) in chapter 2.
127
6. FUEL INJECTION EQUIPMENT
6.1.7 Troubleshooting of fuel injection pump
Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system. If the pump is removed prematurely, the true cause of the trouble may never be known Before removing the pump from the engine, at least go through the basic check points given here.
Basic checkpoints
• Check for breaks or oil leaks throughout the fuel system, from the fuel tank to the nozzle.
• Check the injection timings for all cylinders. Are they correctly adjusted? Are they too fast or too slow?
• Check the nozzle spray.
• Check the fuel delivery Is it in good condition? Loosen the fuel pipe connection at the injection pump inlet, and test operate the fuel feed pump.
6.1.8 Major faults and troubleshooting
1. Engine won’t start
Fault
Fuel not delivered to injection pump
Cause
(1) No fuel in the fuel tank.
(2) Fuel tank cock is closed.
(3) Fuel pipe system is clogged
(4) Fuel filter element is clogged
Fuel delivered to injection pump.
Nozzle doesn’t work.
Injection timing is defective.
(5) Air is sucked into the fuel due to defective connections in the piping from the fuel tank to the fuel pump.
(6) Defective valve contact of feed pump
(7) Piston spring of feed pump is broken.
(8) Inter-spindle or tappets of feed pump are stuck
(1) Defective connection of control lever and accel. rod of injection pump.
(2) Plunger is worn out or stuck.
(3) Delivery valve is stuck
(4) Control rack doesn’t move
(5) Injection pump coupling is damaged, or the key Is broken.
(1) Nozzle valve doesn’t open or close normally
(2) Nozzle seat is defective.
(3) Case nut is loose.
(4) Injection nozzle starting pressure is too low
(5) Nozzle spring is broken.
(6) Fuel oil filter is clogged.
(7) Excessive oil leaks from the nozzle sliding area.
(1) Injection timing is retarded due to failure of the coupling.
(2) Camshaft is excessively worn.
(3) Roller guide incorrectly adjusted or excessively worn.
(4) Plunger is excessively worn.
Remedy
Re-supply
Open
Clean
Disassemble and clean, or replace element
Repair
Repair or replace
Replace
Repair or replace
Repair or adjust
Repair or replace
Repair or replace
Repair or replace
Replace
Repair or replace
Repair or replace
Inspect and tighten
Adjust.
Replace
Repair or replace
Replace the nozzle assembly
Adjust
Replace camshaft
Adjust or replace
Replace plunger assembly
128
6. FUEL INJECTION EQUIPMENT
Fault
2. Engine starts, but immediately stops.
3. Engine’s output is insufficient.
Defective injection timing and other failures.
Nozzle movements is defective.
Injection pump is defective.
4. Idling is rough.
5. Engine runs at high speeds, but cuts out at low speeds.
6. Engine doesn’t reach max. speed
Cause
(1) Fuel pipe is clogged.
(2) Fuel filter is clogged.
(3) Improper air- tightness of the fuel pipe connection. or pipe is broken and air is being sucked in.
(4) Insufficient fuel delivery from the feed pump
(1) Knocking sounds caused by improper (too fast) injection timing.
(2) Engine overheats or emits large amount of smoke due to improper (to slow) injection timing.
(3) Insufficient fuel delivery from feed pump.
(1) Case nut loose.
(2) Defective injection nozzle performance.
(3) Nozzle spring is broken.
(4) Excessive oil leaks from nozzle.
(1) Max delivery limit boll is screwed in too far.
(2) Plunger is worn
(3) Injection amount is not uniform.
(4) Injection timings are not even.
(5) The 1st and 2nd levers of the governor and the control rack or the injection pump are improperly lined up.
(6) Delivery stopper is loose.
(7) Delivery packing is defective.
(8) Delivery valve seat is defective.
(9) Delivery spring is broken.
(1) Movement of control rack is defective.
1) Stiff plunger movement or sticking.
2) Rack and pinion fitting is defective.
3) Movement of governor is improper
4) Delivery stopper is too tight.
(2) Uneven injection volume.
(3) Injection timing is defective.
(4) Plunger is worn and fuel injection adjustment is difficult.
(5) Governor spring is too weak.
(6) Feed pump can’t feed oil at low speeds.
(7) Fuel supply is insufficient at low speeds due to clogging of fuel filter.
(1) The wire or rod of the accel. is caught.
(2) Control rack is caught and can’t be moved.
(1) Governor spring is broken or excessively worn.
(2) Injection performance or nozzle is poor
Remedy
Clean
Disassemble and clean, or replace the element
Replace packing repair pipe
Repair or replace
Inspect and adjust
Inspect and adjust
Repair or replace
Inspect and retighten
Repair or replace nozzle
Replace
Replace nozzle assembly
Adjust
Replace
Adjust
Adjust
Repair
Inspect and retighten
Replace packing
Repair or replace
Replace
Repair or replace
Repair
Repair
Inspect and adjust adjust adjust
Replace
Replace
Repair or replace
Disassemble and clean, or replace element
Inspect and repair
Inspect and repair
Replace
Repair or replace
129
6. FUEL INJECTION EQUIPMENT
8. Engine exhausts too much smoke.
Fault
7. Loud knocking.
When exhaust smoke is black:
When exhaust smoke is white:
Cause
(1) Injection timing is too fast or too slow.
(2) Injection from nozzle is improper.
Fuel drips after each injection.
(3) Injection nozzle starting pressure is too high
(4) Uneven injection.
(5) Engine overheats, or insufficient compression.
(1) Injection timing is too fast.
(2) Air volume intake is insufficient.
(3) The amount of injection is uneven.
(4) Injection from nozzle is improper.
(1) Injection timing is too slow.
(2) Water is mixed in fuel.
(3) Shortage or lube oil in the engine.
(4) Engine is over-cooled.
Adjust
Adjust
Adjust
Adjust
Repair
Remedy
Adjust
Inspect and repair
Adjust
Repair or replace
Adjust
Inspect fuel system, and clean
Repair
Inspect
130
6.1.9 Tools
Name of tool
Pump mounting scale for Yanmar tester 158090-51010 for Bosch (tester) 158090-51020
Shape and size
6. FUEL INJECTION EQUIPMENT
Application
Measuring device
(cam backlash)
158090-51050
Plunger insert
158090-51100
Tappet holder
158090-51200
Weight extractor
158090-51400
131
6. FUEL INJECTION EQUIPMENT
Name of tool
Rack indicator
158090-51500
Shape and size
Rack lock screw
158090-51010
Dummy nut
158090-51520
Nozzle plate
158090-51700
Plunger gauge
121820-92540
Application
Top clearance gauge
158090-51300
Timer extraction tool
132
6. FUEL INJECTION EQUIPMENT
6.2 Fuel Feed Pump
The fuel feed pump pumps fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump.
The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft. It is provided with a manual priming lever so that fuel can be supplied when the engine is stopped.
To fuel filter
From fuel tank
(water separator)
Packing
Fuel feed pump
6.2.1 Construction of fuel feed pump
2 5 4 7 8 9 10 11 12 13 14 15
6
3
1
1. Bottom body
2. Piston spring
3. Piston
4. Diaphragm spring
5. Diaphragm assembly
6. Pin
7. Lever return spring
8. Lever assembly
9. O-ring
10. Stop pin
11. Top body assembly
12. Packing
13. Cover
14. Small screw
15. Cap
6.2.2 Fuel feed pump specifications
Head
Discharge volume
Closed off pressure
1m
230 cm 3 /min at 1500 min -1 (cam), discharge pressure of 0.020 MPa (0.2 kgf/cm 2)
0.029 MPa (0.3 kgf/cm
2)
or more at 400 min
-1
(cam)
133
6. FUEL INJECTION EQUIPMENT
6.2.3 Disassembly and reassembly of fuel feed pump
(1) Disassembly
1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump.
2) Clean the fuel feed pump assembly with fuel oil.
3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
(2) Reassembly
1) Clean all parts with fuel oil, inspect, and replace any defective parts.
2) Replace any packing on parts that have been disassembled.
3) Make sure that the intake valve and discharge valve on upper body are mounted in the proper direction , and that you don’t forget the valve packing.
4) Assemble the diaphragm into the body, making sure the diaphragm mounting holes are lined up
(do not force).
5) Align the match marks on the upper body of the pump and cover, and tighten the small screws evenly.
Tightening torque
N•m(kgf•m)
1.47-2.45 (0.15-0.25)
6.2.4 Fuel feed pump inspection
(1) Place the fuel feed pump in kerosene, cover the discharge port with your finger, move the priming lever and check for air bubbles
(Repair or replace any part which emits air bubbles).
Measuring cylinder
Tappet
Blocked
Air pressure kg/cm 3
Container filled with light oil
(2) Attach a vinyl house to the fuel feed pump intake, keep the pump at the specified depth from the fuel oil surface, move the priming lever by hand and check for sudden spurts of fuel oil from the discharge port. If oil is not spurted out, inspect the diaphragm and diaphragm spring and repair/replace as necessary.
(3) Diaphragm inspection
Parts of the diaphragm that are repeatedly burned will become thinner or deteriorate over a long period of time.
Check the diaphragm and replace if necessary.
Diaphragm
134
(4) Valve contact/mounting
Clean the valve seat and valve with air to remove any foreign matter.
(5) Inspect the diaphragm spring and piston spring for settling and the piston for wear, and replace as necessary.
NOTE: Replace parts as an assembly.
Inlet valve
6. FUEL INJECTION EQUIPMENT
Outlet valve
135
6. FUEL INJECTION EQUIPMENT
6.3 Fuel Filter
The fuel filter is installed between the fuel feed pump and fuel injection pump, and removes dirt/foreign matter from the fuel pumped from the fuel tank.
The fuel filter element must be changed periodiically.
The fuel pumped by the fuel feed pump goes around the element, is fed through the pores in the filter and discharged from the center of the cover. Dirt and foreign matter in the fuel are deposited in the element.
6.3.1 Fuel filter specifications
Filtering method
Filtering area
Maximum flow
Pressure loss
Max. dia. or unfiltered particle filter paper
840 cm 2
1.5 L/min
20 mm Hg or less
10 μ
Inlet from feed pump
Outlet to fuel injection pump
Fuel return pipe joint bolt
(Auto air bleeding)
Element
6.3.2 Fuel filter inspection
The fuel strainer must be cleaned occasionally If there is water or foreign matter in the strainer bowl, disassemble the strainer and wash with clean fuel oil to completely remove foreign matter. Replace the element every 250 hours of operation.
Replace the filter prior to this if the filter is very dirty, deformed or damaged.
8- 6 hole
38
75
10
(0.3937)
M20 X 1.5 Make sure there are
3.5 effective threads
136
6. FUEL INJECTION EQUIPMENT
6.4 Fuel Tank
A triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all models is available as an option.
A fuel return connection is provided on top of the tank of which a rubber hose can be connected to retun fuel from the fuel nozzles.
Fuel return connection
Tank
Level gauge
Pipe joint
Clamp
Rubber hose
Cock
Drain cock
470
Clamp
250
15
362
623
137
PF 1/2
30 36 mm
7. INTAKE AND EXHAUST SYSTEM
7. INTAKE AND EXHAUST SYSTEM
7.1 Intake System
Air enters in the intake silencer mounted at the end of the intake manifold, is fed to the intake manifold and then on to each cylinder.
Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet. After cooling, the exhaust gas enters the mixing elbow, which is directly connected with the exhaust manifold, and is discharged from the ship along with seawater.
When the inside of the intake manifold becomes dirty, intake air resistance is increased and reduces engine power. Periodically check the inside of the intake manifold. In the same way, the intake air silencer should be checked for dirt periodically and cleaned.
When the intake manifold is being attached to the cylinder head, the attachment surfaces should checked for dirt and cleaned. Care should also be taken to insure there is no air leakage.
Do not operate with the intake air silencer removed.
Silencer
Rocker arm cover
Breather pipe
OPTIONAL Air heater
Cylinder head
Intake manifold
7.1.1 Breather system (A reductor to intake air system of blowby gas)
Emitting blowby gas is harmful to natural environment.
Therefore blowby gas reductor is adopted to JH4 series naturally- aspirated engines as breather system.
Some of the combustion gas passes through the clearance between cylinder and piston, and flows to the crankcase. This is said as blowby gas. While it passes into cylinder head and rocker arm cover, the blowby gas mixes with splash oil, and becomes oil mist-blowby gas.
The gas passes through the baffle plate inside a rocker arm cover. And it passes through a diaphragm assy, and reaches a intake silencer. The gas is reduced in the combustion chamber.
Pressure inside a crankcase is controlled by the function of the diaphragm assy, and suitable amount of blowby gas is reduced in intake air system.
[Disassemble]
When a rocker arm cover is taken off, check whether oil or the like enter the diaphragm space from a small hole on the side of a diaphragm cover or not without disassembling the diaphragm.
Spring
Center plate
Diaphragm
Breather pipe
Intake silencer
Diaphragm cover
Rocker arm cover
Breather baffle
Baffle plate
(Breather system component)
Blowby gas flow
Diaphragm
Spring Cover
Center plate
Rocker arm cover
Blowby gas flow to diaphragm space
Baffle plate
Diaphragm part
(Blowby gas flow)
138
7. INTAKE AND EXHAUST SYSTEM
[NOTICE]
1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a diaphragm is damaged, blowby is discharged from the breathing hole on the side of diaphragm cover, and not reduced in the intake manifold. Therefore, be careful of the diaphragm trouble.
2) At lubricating oil replacement or lube oil supply
The amount of lubricating oil isn't to be beyond the standard upper limit (in the engine horizontality, the upper limit mark of the dip stick). Since the blowby gas reductor is adopted, be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine.
[Reassembly]
Replace the diaphragm with new one, when it is damaged.
7.1.2 Diaphragm assy inspection
Refer to 2.2.5(5) for the inspection procedure.
139
7. INTAKE AND EXHAUST SYSTEM
7.2 Exhaust System
7.2.1 Construction
There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. Refer to the exterior diagrams included here.
[Example assembly diagram: L-type mixing elbow.]
U-type
Mixing elbow
Seawater
Seawater
L-type mixing elbow
Gasket
Exhaust manifold
Exhaust manifold
7.2.2 3Mixing elbow inspection
(1) Clean dirt and scale out of the gas and cooling water lines.
(2) Repair crack or damage to welds, or replace.
(3) Inspect the gasket packing and replace as necessary.
140
8. LUBRICATION SYSTEM
8. LUBRICATION SYSTEM
8.1 Lubrication System
The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump, through the holes in the cylinder block and on to the lube oil pump, through the holes in the cylinder block and on to the discharge filter.
The lube oil, which flows from the holes in the cylinder block through the bracket to the oil element, is filtered after the oil cooler. It is fed to main gallery in the cylinder block.
The lube oil which flows in the main gallery goes to the crankshaft journal, lubricates the crank pin from the crankshaft journal, and a option of the oil is fed to the camshaft bearings.
Oil is sent from the gear case camshaft bearings through the holes in the cylinder block and cylinder head to the valve arm shaft to lubricate the valve arm and valves.
Oil is also sent from the main gallery through the intermediate gear bearing (oil) holes to lubricate the intermediate gear bearings and respective gears.
Lube oil for the fuel injection pump is sent by pipe from the main gallery to the fuel injection pump.
Lubricating oil cooler
Oil pressure regulating valve
Lubricating oil pump
Lubricating oil filter
Fuel injection pump
Lubricating oil filter
Oil pressure switch
Cylinder block main gallery
Idle gear shaft Cam shaft bearing Crank journal
Idle gear face Crank pin Valve rocker arm shaft
Valve rocker arm
Tappet and cam face
Oil pan
141
8. LUBRICATION SYSTEM
8.2 Lube Oil Pump
8.2.1 Lube oil pump construction
The trochoid type lube oil pump is mounted in the gear case, and the inner rotor is driven by the crankshaft.
The lube oil flows from the intake filter mounted on the bottom of the cylinder block through the holes in the cylinder block and engine plate, and out from the holes in the engine plate and cylinder block to the discharge filter.
The lube oil pump is fitted with a control valve, which controls the discharge pressure at 0.29MPa (3kgf/cm 2 ).
Crankshaft
Pump cover
Control valve
Plug
Outer rotor
Inner rotor
Gear case
8.2.2 Specifications of lube oil pump
Lube oil pump specifications
Engine speed
Pump speed
Delivery quantity
Delivery pressure
Oil temp.
3000 (min -1 )
3000 (min -1 )
º 17.5 (l/min)
0.39-0.54MPa (4.0-5.5kgf/cm 2 )
¹ 115 (°C)
800 (min -1 )
772 (min -1 )
º 8.0 (l/min)
º 0.06MPa (0.6kgf/cm 2 )
8.2.3 Lube oil pump disassembly and reassembly
Disassembly
(1) Remove the crankshaft pulley.
(2) Remove the gear case from the gear case flange.
(3) Remove the lube oil pump cover from the gear case. Do not disassemble the inner / outer rotors, and check that the pump rotates smoothly.
(4) The oil pressure control valve plug is coated with adhesive and screwed in, so it cannot be disassembled. These parts cannot be reused after disassembly.
Replace if necessary as an assembly.
Reassembly
[NOTICE]
Always check if the pump rotates smoothly after installation on the gear case.
Running the engine when the pump rotation is heavy may cause the pump to be burnt.
(1) Apply lube oil to rotor (outer/inner) insertion part.
(2) Assemble the outer rotor so that the mark of the end face may become a cover side when inserting it in the gear case.
(3) Fasten the pump cover by the standard torque.
Tightening torque
5.4-8.4 N•m
(0.55-0.85 kgf•m)
(4) When replacing the lube oil pump, replace the whole assy.
142
8. LUBRICATION SYSTEM
8.2.4 Lube oil pump inspection
(1) Outside clearance of outer rotor
Insert a gap gage between a outer rotor and a pump body, and measure the clearance.
mm Outside clearance
Standard
0.12-0.21
Limit
0.30
Gear case
Outer rotor
(Outer diameter clearance)
(2) Side clearance of outer rotor
When measuring a side clearance, put a right-angle gage to the pump body, insert a gap gage and measure the clearance.
mm Side clearance
Standard
0.02-0.07
Limit
0.12
(3) Inner rotor and gear boss clearance
(Side clearance)
Width across flat of rotor
Crank gear
Rotor inner diameter
Inner rotor
Item Part
Inside clearance of inner rotor
Width across flat clearance of inner rotor
Gear boss diameter
Rotor inner diameter
Width across flat of gear boss
Width across flat of rotor
Standard dimension
(mm)
53.05-53.15
53.45-53.55
49.45-49.75
49.95-50.05
Standard clearance
(mm)
Standard clearance limit
(mm)
0.3-0.5
0.6
0.2-0.6
0.7
8.2.5 Oil pressure control valve construction
The oil pressure control valve attached with lube oil pump controls the oil pressure from the time the lube oil leaves the filter and is cooled in the lube oil cooler until just before it enters the cylinder body main gallery.
When the pressure of lube oil entering the cylinder body main gallery exceeds the standard, the control valve piston opens the bypass hole and lube oil flows back into the oil pan.
Standard oil pressure
0.39-0.54 MPa
(4.0-5.5kgf/cm
2
)
143
8. LUBRICATION SYSTEM
8.3 Lube Oil Filter
8.3.1 Lube oil filter construction
The lube oil filter is a full-flow paper element type.
mounted to the side of the cylinder body with the filter bracket. The cartridge type filter is easy to remove.
To prevent seizure in the event of the filter clogging up, a bypass circuit is provided in the oil filter. The bypass valve in the filter element opens when the difference in the pressure in front and behind the paper element reaches 0.8-1.2kg/cm
2
.
Type
Filtration area
Discharge volume
Pressure loss
By-pass valve opening pressure
Full flow, paper element
0.069 m
2
20 l/min
0.01-0.03 MPa
(0.1-0.3 kgf/cm
2
)
0.08-0.12 MPa
(0.8-1.2 kgf/cm 2 )
Cylinder block
Joint
Clamp
Fresh water
Filter bracket
Gasket
To fresh water pump
Drain cock
Clamp
Bolt
Clamp
Lube oil cooler
Lube oil cooler nut
Lube oil filter
(Lube oil filter and cooler)
8.3.2 Lube oil filter replacement
Refer to 2.2.2(2).
8.4 Lube oil Cooler
8.4.1 Lube oil cooler construction
The lube oil cooler is located between lube oil filter and filter bracket as shown in the above figure.
The lube oil is cooled by fresh water.
8.4.2 Inspecting the lube oil cooler
(1) Clean the cooling water path (fresh water) of the lube oil cooler to prevent the buildup of scale
(2) If the rubber hose connection or welds are corroded, repair or replace the cooler
(3) Apply the following water pressures to the seawater path and lube oil lines to check for any leakage. Repair or replace the cooler if there are any leaks.
Lubricating oil circuit
Seawater path
Test pressure
0.15 MPa (1.5 kgf/cm 2 )
0.4 MPa (4 kgf/cm
2
)
144
8. LUBRICATION SYSTEM
8.5 Rotary Waste Oil Pump (Optional)
A rotary waste oil pump to pump out waste oil is available as an option.
Rotary waste oil pump
Delivery capacity pen one revolution
Delivery pressure
Suction head
Part No.
0.057 L
0.15 MPa (1.5 kg/cm 2 ) or below less than 1m
124413-39100
Oil inlet pipe
Outside dia. 16 mm
145
9. Cooling Water System
9. Cooling Water System
9.1 Cooling Water System
The cooling water system is of the indirect seawater cooled, fresh water circulation type. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater.
Seawater pumped in from the sea by the seawater pump goes to the heat exchanger, where it cools the fresh water. Then it is sent to the mixing elbow and is discharged from the ship with the exhaust gas.
Fresh water is pumped by the fresh water to the cylinder jacket to cool the cylinders, and the cylinder head. The fresh water pump body also serves as a discharge passageway (line) at the cylinder head outlet. and is fitted with a thermostat.
The thermostat is closed when the fresh water temperature is low, immediately after the engine is started and during low load operation, etc. Then the fresh water flows to the fresh water pump inlet, and is circulated inside the engine without passing through the heat exchanger.
When the temperature of the fresh water rises, the thermostat opens, fresh water flows to the heat exchanger, and it is then caoled by the seawater in the tubes as it flows through the cooling pine. The temperature of it flows through the cooling pine. The temperature of the fresh water is thus kept within a constant range by the thermostat.
Seawater circuit
Fresh water circuit
Coolant recovery tank
Heat exchanger
Mixing elbow
Thermostat
Cylinder head
P
Cylinder block
Fresh water pump
Lube oil cooler
P
Seawater pump
Sea cock
146
Fresh water line
Filler cap
Coolant recovery tank
Exhaust manifold
Heat exchanger
Water temperature sender
Fresh water pump
Inlet for water heater
From lube oil cooler
Water temperature switch
(Fresh water pipe)
9. Cooling Water System
Seawater line
Mixing elbow
Heat exchanger
Seawater pump
(Seawater pipe)
Seawater inlet
147
9. Cooling Water System
9.2 Seawater Pump
The seawater pump is driven by a gear. The two kinds of seawater pumps are prepared. The standard one is mounted on the gear case and the other (optional) is mounted on the gear case flange.
(Option)
Seawater pump
Pump drive gear
Pump drive gear
Gear case flange
Gear case
Gear case
Seawater pump
9.2.1 Specifications of seawater pump
(1) Performance
Flow
Self-priming ability
Tightness test
Min. 3800 L/h at pin = -5 kPa (-0.05 bar) pout = 95 kPa (0.95 bar) n = 3250 min
-1 after 1500h duty
Max. 10 s at
Suction head = 0.5 m length of pipe = 0.6 m n = 500 min -1
400 kPa (4bar)
(2) Durability (reference data)
• Impeller
• Flow drop
Leakage from seal
Min. 1500 h
Max. 10% after 1000h
Max. cm 3 /h
Lip seal, water
Lip seal, oil
Cover, wear plate
Other parts
1000 h
3000 h
Min. 3000 h
Min. 6000 h
148
9. Cooling Water System
9.2.2 Seawater pump disassembly
Refer to 2.2.4.(5).
(1) Remove the rubber hose from the seawater pump outlet and then the seawater pump assembly from the gear case.
(2) Remove the seawater pump cover and take out the O-ring, impeller and wear plate,
(3) Remove the mechanical seal side stop ring.
(4) Insert pliers from the drive gear long hole and remove the stop ring that holds the bearings.
(5) Lightly tap the pump shaft from the impeller side and remove the pump shaft, bearings, and drive gear as a set.
(6) Remove the oil seal and mechanical seal if necessary.
9.2.3 Seawater pump Inspection
(Refer to 2.2.4(5).)
(1) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace if necessary.
Cover
O-ring
Impeller
Wear plate
Pump body
(Sea water pump)
(2) Inspect the mechanical seal and replace if the spring is damaged, or the seal is corroded. Also replace the mechanical seal if there is considerable water leakage during operation.
Cooling water leakage less than 3 cm 3 /h
(3) Make sure the ball bearings rotate smoothly. Replace if there is excessive play.
9.2.4 Seawater pump reassembly
(1) When replacing the mechanical seal, coat the No.1101 oil seal and pressure fit Coat the sliding surface with a good quality silicon oil, taking sufficient care not to cause any scratches.
(2) When replacing the oil seal, coat with grease and insert.
(3) Mount the pump shaft, ball bearing and gear assembly to the pump unit and fit the bearing stop ring. Be sure not to forget the water O-ring when doing this.
NOTE: Coat the shaft with grease.
(4) After inserting the mechanical seal stop ring, mount the wear plate and impeller.
(5) Mount the O-ring and the cover.
NOTE: Replace the O-ring with new one.
149
9. Cooling Water System
9.3 Fresh Water Pump
9.3.1 Fresh water pump construction
The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinders and cylinder head.
The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal. The V pulley on the end of the pump shaft is driven by a V belt from the crankshaft.
The bearing unit assembled in the pump shaft uses grease lubricated ball bearings and cannot be disassembled.
The totally enclosed mechanical seal spring presses the impeller seal mounted on the impeller side away from the pump body side. This prevents water from leaking along the pump shaft.
As the impeller and pulley flanges are press fit assembled, they cannot be disassembled.
Cylinder head
Thermostat
From oil cooler
From heat exchanger
(fresh water tank)
To cylinder block
O-ring Fresh water pump
Spacer
To heat exchanger
(fresh water tank)
For water temperature switch
Thermostat
Bearing unit
For sender unit
V-pulley
Spacer
Pump plate
Gasket
Impeller
Bypass port
V-pulley flange
Pump body
Mechanical seal
Gasket
To cylinder body
O-ring
Pipe flange
150
9. Cooling Water System
9.3.2 Specifications of fresh water pump
Pulley ratio
(crank shaft/pump shaft)
Pump shaft speed(Max)
Delivery capacity
Total head
Ø120/Ø120
4020 min
-1
70 L/min
4 m
9.3.3 Fresh water pump disassembly
(1) Do not disassemble the fresh water pump. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Replace the pump as an assembly in the event of trouble.
(2) When removing the fresh water pipe as an assembly from the cylinder and cylinder head, replace the cylinder intake pipe O-ring.
(3) When the fresh water pump and pump body and cylinder intake flange and/or fresh water pump and pump plate are disassembled, retighten to the specified torque.
Tightening torque for pump setting bolts
687-1080 N•cm
(70-110 kgf•cm)
9.3.4 Fresh water pump inspection
(1) Bearing unit inspection
Rotate the impeller smoothly. If the rotation is not smooth or abnormal noise is head due to excessive bearing play or contact with other parts, replace the pump as an assembly
(2) Impeller inspection
Check the impeller blade, and replace if damaged or corroded. or if the impeller blade is worn due to contact with pump body.
(3) Check the holes in the cooling water and bypass lines, clean out any dirt or other foreign matter and repair as necessary.
(4) Replace the pump as an assembly if there is excessive water leakage due to mechanical seal or impeller seal wear or damage.
(5) Inspect the fresh water pump body and flange, clean off scale and rust, and replace if corroded.
(6) Measure the clearance between the Impeller and the pump body, by pushing the impeller all the way towards the body, and inserting a thickness gauge diagonally between the impeller and the body.
Measure the clearance between the impeller and the plate (pump body bracket) by placing a straight-edge against the end of the pump body and inserting a thickness gauge between the impeller and the straight-edge.
151
9. Cooling Water System
Measuring clearance between impeller and pump body.
Measuring clearance between impeller and pump body bracket.
Standard Limit mm
Clearance between impeller and body
Clearance between impeller and plate
0.3-1.1
15
1.5
-
Thickness gauge
Straightedge
Thickness gauge
152
9. Cooling Water System
9.4 Heat Exchanger
9.4.1 Heat exchanger construction
The heat exchanger cools the hot fresh water, that has cooled the inside of the engine, with seawater.
The cooler core consists of many small diameter tubes, baffle plates and tube cover.
The seawater flows through the maze formed by the baffle plates.
There is a reservoir below the cooler core, which serves as the fresh water tank. There is an exhaust gas passageway in the reservoir, which forms a water cooled exhaust manifold.
The pressure cap (filler cap) on top of the heat exchanger has a pressure valve, which lets off steam through the overflow pipe when pressure in the fresh water system exceeds the specified value. It also takes in air from the overflow pipe when pressure in the fresh water system drops below the normal value.
9.4.2 Specifications of heat exchanger
Tube dia.
MODEL
Tube surface area
Fresh water flow
Sea water flow
Fresh water velocity
Sea water velocity
UNIT mm m 2
L/hr
L/hr m/s m/s
3JH4E
Ø6/Ø5 x 54
0.193
3300
3080
0.99
1.61
Side cover
Gasket
O-ring
Cooler core
Filler neck
Pressure cap
Overflow pipe
O-ring
Side cover
9.4.3 Disassembly and reassembly of the heat exchanger
(1) Remove the side covers on both sides of the cooler core and take out the cooler core and O-ring(s).
NOTE: Replace the O-ring(s) when you have removed the cooling pipe.
(2) Remove the pressure cap
NOTE: Don’t remove the filler neck.
9.4.4 Heat exchanger inspection
Refer to 2.2.5(4).
153
9. Cooling Water System
9.5 Pressure cap and coolant recovery tank
9.5.1 Pressure cap construction
The pressure cap mounted on the fresh water filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating. The top seal of the cap seals the top of the filler neck, and the pressure valve seals the lock seat.
9.5.2 Pressure cap pressure control
The pressure valve and vacuum seal both seal the valve seat when the pressure in the fresh water system is within the specified value of 0.9kg/cm 2 . This seals the fresh water system.
When the pressure within the fresh water system exceeds the specified value, the pressure valve opens, and steam is discharged through the overflow pipe.
When the fresh water is cooled and the pressure within the fresh water system drops below the normal value, atmospheric pressure opens the vacuum valve, and air is drawn in through the overflow pipe.
The coolant recovery tank (which sill be described later), keeps the water level from dropping due to discharge of steam when the pressure valve opens.
Action of pressure control valve
Action of pressure control valve
Pressure valve
Vacuum valve
Open at 82-109 kPa
(0.84-1.11 kgf/cm
2
, 0.82-1.09 bar)
Open at 8 kPa
(0.08 kgf/cm 2 , 0.08 bar) or below
9.5.3 Pressure cap inspection
Refer to 2.2.5(4).
Pressure cap
Pressure valve spring
Filler neck
Overflow pipe
Fresh water cooler Copper tube
154
9. Cooling Water System
9.5.4 Replacing filler neck
1) Take out the copper tube inside the filler neck with striking a circumference with a driver and so on.
When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it.
2) Clean both of new filler neck and the insertion part of fresh water cooler with T7471 type activation spray or equivalent.
3) Apply Loctite 601 glue or equivalent on filler neck outside and press the filler neck into the fresh water cooler with the special tool.
Tool1
Press the filler neck
Filler neck
4) To fix the filler neck on the fresh water cooler, press the small copper tube inside the filler neck with the special tool.
Note:
The top of this tube should be under the sealing surface of the filler neck for the pressure cap.
5) Fit the pressure cap on the filler neck.
Filler neck Part No.
129673-44110
Copper tube Part No.
129673-44150
Refer to 4.2.2 for tool 1 and tool 2.
Fresh water cooler Loctite 601
Tool2
Press the copper tube in the filler neck
Copper tube
155
9. Cooling Water System
9.5.5 Function of the coolant recovery tank
The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 82-109 kPa (0.84-1.11 kgf/cm 2 ).
This consumes water. The coolant recovery tank maintains the water level by preventing this discharge of water.
The steam discharged into the coolant recovery tank condenses into watch, and the water level in the tank rises.
When the pressure in the fresh water system drops below the normal value, the water in the coolant recovery tank is sucked back into the fresh water tank to raise the water back to its original level.
The coolant recovery tank facilitates long hours of operation without water replacement and eliminates the possibility of burns when the steam is ejected from the filler neck because the pressure cap does not need to be removed.
Coolant recovery tank
65
60
30
8
9.5.6 Specifications of coolant recovery tank
Capacity of coolant recovery tank
Overall capacity
Full-scale position
Low-scale position
1.3 L
0.8 L
0.2 L
Filler cap
61
FULL
LOW
120 mm
9.5.7 Mounting the coolant recovery tank
(1) The coolant recovery tank is mounted at approximately the same height as the heat exchanger (fresh water tank).
(allowable difference in height : 300mm (11.8110 in.) or less)
(2) The overflow pipe should be less than
1000mm (39.3701in) long, and mounted so that it does not sag or bend.
NOTE : Make sure that the overflow pipe of the coolant recovery tank is not submerged in bilge If the overflow pipe is submerged in bilge, water in the bilge will be siphoned into the fresh water tank when the wafer is being cooled.
Overflow tube
Mounting plate
Sub tank
9.5.8 Precautions on usage of the coolant recovery tank
(1) Check the coolant recovery tank when the engine is cool and refill with fresh water as necessary to bring the water level between the low and full marks.
(2) Check the overflow pipe and replace if bent or cracked Clean out the pipe if it is clogged up.
156
9. Cooling Water System
9.6 Thermostat
9.6.1 Functioning of thermostat
The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level.
The thermostat is bottom bypass type It is located in a position connected with the cylinder head outlet line at the top of the top of fresh water pump unit.
When the fresh water temperature exceeds the above temperature, the thermostat opens, and a portion of the water is sent to the heat exchanger and cooled by seawater, the other portion going from the bypass line to the fresh water pump intake.
The bypass line is closed off as the thermostat valve opens and is completely closed when the fresh water temperature reaches 81.5
° C (valve lifts 4mm (0.1575in)), sending all of the water to the heat exchanger.
9.6.2 Thermostat construction
The thermostat used in this engine is of the wax pellet type, with a solid wax pellet located in a small chamber.
When the temperature of the cooling water rises, the wax melts and increases in volume. This expansion and construction is used to open and close the valve
9.6.3 Characteristics of thermostat
Opening temperature
Full open temperature
Valve lift at full open
Bypass valve lift
Bypass valve close temperature
75-78°C
90°C
8 mm
3.7 mm
81.5°C
Thermostat cover
Gasket
Thermostat
Gasket
9.6.4 Thermostat inspection
Remove the thermostat cover on top of the fresh water pump and take out the thermostat. Clean off scale and rust and inspect, and replace if the characteristics
(performance) have changed, or if the spring is broken, deformed ar corroded.
9.6.5 Testing the thermostat
Refer to 2.5 in chapter 2.
Fresh water pump body
157
9. Cooling Water System
9.7 Bilge Pump and Bilge Strainer (Optional)
9.7.1 Introduction
(1) General Introduction
Name
Time
Rotation direction
Weight
Negative pressure detector
Temperature
Bilge pump
10 minutes
Right (viewed from the impeller side)
Pump 1.4kg
Diaphragm type
-30°C-80°C
(2) Exterior
Motor assy
Controller
White
Outlet
Green
Red
Blue
Strainer
Inlet
Red (+)
White (-)
Battery
Pump dimensions
Length
Yoke diameter
Assembly hole diameter
Assembly pitch
225 mm
Ø61
Ø5.3
50 x 90 mm
158
9. Cooling Water System
9.7.2 Description
(1) Characteristics
1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater.
2) Automatic feeding height : 1 m or greater
(Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m)
3) Automatic feeding time : 2 5secs.
(Limit for automatic feeding time: new pump with inside parts wet, approx. 1 sec.)
4) Automatic stopping : Air intake causes negative pressure triggering automatic stopping.
(2) Insulation
1) Insulation resistance : 500V with a megatester when the difference between the continuity point and the body is 1M Ω or greater.
2) Insulation proof stress : AC50 between the continuity point and the body, or 60hz 500V for 1minute when impressed current leakage is 10mA or lower.
(3) Durability
Rated voltage when there is 3% salt water 60L + engine oil 3%, and operation is at 1800 cycles and there are no difficulties.
(4) Vibration proof
Amplitude 0.51mm(one side of the amplitude)
Vibration frequency 10-55Hz
Sweep time 90secs.
Direction of vibration each direction 4 hours
No difficulties after test period
9.7.3 Cautions
(1) Attach at a position higher than the bilge water away from rain or other water, and 50-
70cm above the bottom of the boat.
(2) Never run the pump dry. Be sure that the strainer is inserted in the drain water before pushing the switch. If no water is being drawn up after a period of 10 seconds or more, prime the pump. (Do not run the pump for longer than 10 seconds when no water is being drawn up.)
(3) When the pump has not been used for a long period of time, the inside of the pump will be dry and drawing ability will be lowered. Before reusing, clean the inside of the pump or prime it to insure that it is wet, and check to be sure that the pump is then operating correctly.
(4) When charging the diesel engine oil, wait a period of 30 minutes or longer from the time of stopping (oil temperature 20-70°C). Refrain from operation when the oil temperature is below 15°C, or above 50°C.
(5) When the bilge inside the pump or hose freezes, completely melt the water with a steaming towel before beginning operation. When the temperature inside the pump is low, it will take a longer amount of time for the pump to drain off the bilge.
(6) The impeller replacement kit includes one impeller and 3 washers for adjusting the side gap. If after replacing the impeller the pump does not drain, place side gap adjustment washers underneath the bottom plate to adjust. Select the number of washers used in accordance with the following. (When the pump is draining, the electric current load is about 5A. When there are too many washers, the electric current value will be too great and will blow a fuse.)
159
9. Cooling Water System
(7) The pump cannot be used to drain off rain water or large amounts of flood water. The pump can be run continuously for a period of 10 minutes After this time it must shut off for a period of 2 hours before reusing.
(8) Do not use the pump for showering.
If the pump outlet is deformed for showering, the increase in water pressure will increase the load on the motor and cause motor seizure.
(9) Fix the strainer so that it well not turn upside down or on its side.
(10) When sludge has built up in the bilge to be drained, position the strainer about 20mm above the sludge. When the pump is stopped, be sure there is no sludge remaining inside the pump.
(11) The specific gravity for the battery fluid is 1.25 or more.
9.7.4 Assembly Procedure
When bilge is being used, assemble in accordance with the following.
(1) Assembling the bilge pump
• Select a dry place above the bilge water level.
• Select the location for the bilge pump taking into consideration the length of the switch cable
(approx. 3m) and its attachment point, and the position of the battery.
• Position at a 45° angle as shown in the illustration with the nozzle facing up, and 50-70cm from the bottom of the boat.
5X12 screw, 4 each
Bilge pomp
Bilge
(2) Assembling the switch
• Attach in a place to insure easy operation away from rainwater.
• Connect the terminal to the battery.
(When the cord will not reach the battery, and extension of no greater than 3m length stable for
AV3mm
2
can be attached.)
5X12 screw,
Controller
45
50 70 cm
2mm 2
AV2wire Red (+)
2mm 2
AV2wire White (-)
(-)
(3) Positioning the strainer
• Attach at the place where the greatest amount of water is collected when the boat is stopped.
• It is best to place the strainer as close to the bilge pump as possible. Cut the 3m hose to a length of
1.2m-1.8m and attach allowing plenty of give.
• Check the strainer during a test operation before screwing firmly into place.
(When the strainer is screwed in, be especially careful not to damage the bottom of the boat.)
• The strainer contains a weight, and can be used with the weight in place.
• Always keep the strainer clean.
160
4X16 screw, 1 each
9. Cooling Water System
(4) Attaching the delivery nozzle (outlet)
• Make a fixing hole of Ø21 or less for attaching the nozzle. The hose attached at the nozzle should be
1.8m or less and should reach without any strain, therefore care should be taken in deciding on the best position.
• Fix the nozzle (outlet) in place and attach on the discharge side of the pump.
Fixing hole
(5) Attaching the hose
• Attach the hose from the strainer to the pump inlet.
• Attach the delivery nozzle hose to the pump outlet.
• Make the hose as short as possible and avoid sharp bends.
21
Hose
Delivery nozzle
(6) Test operation
• Collect water in the bottom of the boat, and check for any problems with the hose or siring. After doing this, connect the battery.
• Turn on the pump switch, and check to see that water is being taken in and discharged properly.
The pump will stop automatically when there is no water left.
• If the inside of the pump is dry, or if the water is not being drawn up initially after a period of 10 seconds, lift the strainer above the water surface and stop the pump. Prime the pump before starting it up again.
(7) Fixing the strainer
• After the test operation, fix the strainer into place with screws.
(Be careful not to damage the bottom of the boat with the screws.)
161
9. Cooling Water System
9.7.5 Cautions for Assembling
Observe the following cautions for handling.
• Do not use gasoline or solvents.
1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil
• Never run when there is no water in the bilge.
Check to be sure that the strainer is in the water before turning on the switch.
• Keep the cord terminal away from the water. Water inside the motor or switch may lead to damage.
When the insulation around the cord is damaged, water can seep in to the wires; thus, care should be taken not to scratch or nick the cord.
• When the pump has not been used for a long period of time, the inside of the pump will be dry and it may not operate properly at first. If after10 seconds the pump is not working, turn off the switch and prime the pump before trying again.
(Never run the pump dry for period of greater than10 seconds.)
• Replace the diesel engine oil only after the engine has been stopped for a period of 30 minutes (oil temp. 20-70°C). Whenever possible refrain from operation when the oil temperature is below 15°C or above 50°C.
• Bilge water left in the hose or inside the pump can freeze, and care should be taken to see that any excess bilge is completely discharged If bilge water should freeze, and care should be taken to see that any excess bilge is completely discharged. If bilge water should freeze inside the hose or pump, it should be completely melted before starting up the pump. When the temperature inside the pump is low, it will take a longer time for the pump to operate. (0°C, 5-10 seconds.)
• Keep the pump in a dry place away from rain or other water.
• Use the regulation hose; do no use thin vinyl hose or hose which is not heat-resistant.
• The pump cannot be used to drain off rainwater or large quantities of flood water. This pump can be operated continuously for a period of 10 minutes.
• Do not use the pump for showering.
If the pump outlet is deformed for showering, the increase in water pressure will increase the load on the motor and cause motor seizure.
• When sludge has built up in the bilge to be drained, position the strainer about 20cm above the sludge. When the pump is stopped, be sure there is sludge remaining inside the pump housing.
• The specific gravity for the battery fluid is 1.25.
• Refer to your local dealer for impeller replacement.
The local dealer will perform the following.
The impeller replacement kit includes one impeller and 3 films for adjusting the side gap. If after replacing the impeller the pump does not drain, place side gap adjustment washers underneath the bottom plate to adjust. Select the number of films used in accordance with the following. (When the pump is draining, the electric current load is about 10A for 12V and 5A for 24V. The pump operates efficiently at these electric current loads.)
Steps for replacement
1) Remove the impeller plate by taking out the M4 screws (4) and opening the top of the diaphragm switch and the.
(Screw lock has been applied to the screw, and a dryer should be used to heat the screw before removing it.)
2) Clean the inside of the pump.
3) Grease the plate, impeller, and film for side gap adjustment, and then reassemble the pump by inserting first the film plate and then the impeller.
162
9. Cooling Water System
9.7.6 Troubleshooting
Refer to the following countermeasures for difficulties that arise.
Problem
1. Pump does not turn
2. Pump turns but does not draw up water.
3. Pump turns, but the amount of discharge is low.
4. Water leakage from pump
5. Pump draws up bilge, but motor stops when hand is removed from starter switch.
6. Motor does not stop, when there is no bilge water left
Faulty wiring
Faulty battery
Cause
Faulty starter switch
Faulty pump
Draws up air.
Low voltage in battery.
The distance between the pump and the surface of the water is too great.
The pump is too high.
Pump intake is weak.
Clogged strainer
Hose is broken or damaged.
Water leakage from packing
Faulty pump seal
Faulty diaphragm switch
Damaged diaphragm switch
Clogged strainer or hose
Damaged diaphragm switch
Countermeasure
Check the wiring between the motor and battery.
Check to see if the specific gravity of the battery fluid is greater than
1.25.
Recharge or replace the battery.
Consult your local dealer.
Consult your local dealer.
Check hose connections.
Retighten pump screws.
Check to see if the specific grabity of the battery fluid is greater than
1.25.
Recharge or replace the battery.
Lower the pump. (Position the pump so that it is closer to the surface of the water.)
Lower the pump. (Position the pump so that it is 50-70cm above the bottom of the boat.)
If intake is still faulty after priming, consult your local dealer.
Clean strainer.
Check for damage and repair. If incorrect hose has been used, replace with the regulation type of hose.
Retighten pump screws.
Consult your local dealer.
Check for loose wiring in diaphragm switch and correct.
Consult your local dealer.
Clean strainer or hose.
Check for continuity of diaphragm switch terminal.
Consult your local dealer if there is continuity.
163
10. Reduction and Reversing Gear
10. Reduction and Reversing Gear
Marine gear KM35P and KM35A are applied to the 3JH4E series engines.
Refer to chapter 7 in the service manual of 3JH3/4JH3 engines for inspection, disassembly and reassembly.
Specifications
Model
For engine models
Clutch
Reduction ratio
Forward
Reverse
Propeller shaft speed
(at continuous power, Forward) min
-1
Direction of rotation
Input shaft
Output shaft Forward
Reverse
Remote control
Control head
Cable
Clamp
Cable connector
Output shaft coupling
Outer diameter
Pitch circle diameter
Connecting bolt holes
Position of shift lever , viewed from stern
Lubricating oil
Lubricating oil capacity
Dry mass
KM35P KM35A
3JH4E 3JH4BE
Constant mesh gear with servo cone clutch (wet type)
2.36
3.16
2.61
3.16
2.33
3.04
2.64
3.04
1232 1114 1246
Counter-clockwise, viewed from stern
Clockwise, viewed from stern
Counter-clockwise, viewed from stern
Single lever control
Morse. 33-C (cable travel 76.2mm)
YANMAR made. standard accessory
YANMAR made. standard accessory
100mm
78mm
4-10.5mm
Left side Right side
API CC class, SAE 20/30
0.5 liters 0.65 liters
12kg 13kg
1103
164
11. REMOTE CONTROL (OPTIONAL)
11. REMOTE CONTROL (OPTIONAL)
11.1 Remote Control system
11.1.1 Construction of remote control system
The remote control permits one handed control of the engine speed changing from forward to reverse, and stopping.
Fittings which allow for easy connection of the remote control cables with the fuel injection pump and transmission are provided with the remote control set.
The use of Morse remote control cables, clamps and a remote control head, are also provided for The device to stop the engine is electric and will be explained under the section on electrical equipment.
11.1.2 Remote control device components
Remote control head
Remote control cable
Engine stop cable
Morse description
Morse MT3 top mounting single lever
Morse MN side mounting single lever
Morse 33C x 4m
Morse 33C x 7m
Yanmar 4m
Yanmar 7m
(1) Remote control handle
The model MT-3 remote control has been designed so that operation of the clutch (shift) and governor (throttle) can be effected with one lever.
Two cables are required for the MT-2 single, one for the clutch and the other for the governor.
When warming up the engine, to freely control the governor separately from the clutch put the lever inneutral, the central position. and pull the knob in the center of the control lever. When the lever is returned to the neutral position, the knob automatically returns to its original position, and the clutch is free. The governor can then be freely operated.
MT-3 Type
The MN type controller has been designed so that operation of the clutch and throttle can be effected with one lever. When the button next to the control lever is pulled out with the lever in the central position, it holds the clutch in the neutral position so that the throttle can be opened all the way and warm up the engine. When the engine is warmed up, return the handle to the central position and push the button back in. Control of the clutch and throttle is thus effected with one handle.
165
MN Type
11. REMOTE CONTROL (OPTIONAL)
(2) Remote control cable
Use only Super Responsive Morse Control Cables
These are designed specifically for use with Morse control heads. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash.
33C
166
11.2 Remote Control Installation
(1) Speed control
Remote control handle
11. REMOTE CONTROL (OPTIONAL)
Governor
Clamp
Cable bracket
Remote control cable
Cable joint
Control lever
Remote control bracket
167
11. REMOTE CONTROL (OPTIONAL)
(2) Clutch control
Neutral
S1 S2
Reverse Forward
Remote control head
Cable clamp
Bolt
Lock nut
Oil seal
Washer
Shift lever
Split pin
Pivot
Bolt (M8 X 25)
To engine speed
Note : ( ) Cable shift travel
S1 = More than 36 mm (1.42")
S2 = More than 36 mm (1.42")
Clamp
To marine gear
(3) Engine stop
Usually, to stop the engine, the stop button of an instrument panel is pushed, and the engine is stopped.
Alternatively, the emergency stop button behind the stop solenoid can be pushed, and the engine is stopped.
Shims
Stopper bolt
Bolt (M8 X 25)
(KM35P marine gear)
Emergency stop button
Governor
Stop solenoid
O-ring
168
11. REMOTE CONTROL (OPTIONAL)
11.3 Remote Control Inspection
(1) When the control lever movement does not coincide with operation of the engine, check the cable end stop nut to see whither or not it is loose, and readjust/retighten when necessary.
Throttle
Reverse
Shim in
Neutral
Shim in
Forward
Throttle
Free throttle
(2) Too many bends (turns) in the cable or bends at too extreme and angle will make it difficult to turn the handle. Reroute the cable to reduce the number of bends of enlarge the bending radius as much as possible (to 200mm or more).
(3) Check for loose cable bracket/clamp bolts or nuts and retighten as necessary.
(4) Check cable connection screw heads, cable sleeves and other metal parts for rust or corrosion. Clean off minor rust and wax or grease the parts. Replace if the parts are heavily rusted or corroded.
169
11. REMOTE CONTROL (OPTIONAL)
11.4 Remote Control Adjustment
(1) Shift lever adjustment
Move the lever several times-the movement of the clutch lever on the engine from forward, neutral and reverse must coincide with the forward, neutral and reverse on the control lever. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side).
(2) Throttle lever adjustment
Move the control lever all the way to full throttle several times, and then return. The throttle lever on the engine must lightly push against the idle switch when it is returned If it is property adjusted, the knob can be easily pulled out when the lever is in the neutral position, and will automatically return when the control lever is brought back to the neutral position If the control lever presses too hard against the knob, it may not return automatically, in which case the cable end must be adjusted as explained for the clutch.
The knob cannot be pulled out when the lever is not in the neutral (central) position.
170
12. Electrical System
12. Electrical System
12.1 Electrical System
Alternator
Neutral safety switch
(Fitting to marine gear)
Battery switch
Battery
Starting motor
Optional
Starter B terminal
Starter S terminal
Earth bolt
Magnetic relay Safety relay
Flywheel housing
Optional
C.W. temp. sensor
C.W. temp. switch
Optional
Air heater
(Intake manifold)
Relay
Optional
Stop solenoid
Extension wire harness
S T O P
10
20
0
30
40
50
G L O W
O F F
O N
S T A R T
Sail drive
2 place expression (optional)
171
12. Electrical System
12.1.1 Wiring diagram
(1) For B-type instrument panel
(Color coding)
R
B
W
L
RB
LB
Red
Black
White
Blue
Red / Black
Blue / Black
YW Yellow / White
YB Yellow / Black
YG Yellow / Green
WL White / Blue
WB White / Black
WG White / Green
GR
O
Green / Red
Orange
WBr White / Brown
1 Starter switch
2 Stop switch
3 Tachometer / Hour meter
4 Buzzer
5 Lubricating oil low pressure alarm
6 Coolant high temperature alarm
7 Water in sail drive seal alarm
8 Battery low charge alarm
9 Relay (for 2 station : Option)
10 Fuse (3A)
11 Starter switch
12 Stop switch
13 Tachometer / Hour meter
14 Buzzer
15 Lubricating oil low pressure alarm
16 Coolant high temperature alarm
17 Water in sail drive seal alarm
18 Battery low charge alarm
19 -
20 -
21 Air heater (Option)
22 Engine stop solenoid
23 Stop relay
24 Starter relay
25 Starter
26 Coolant high temperature switch
27 Lubricating oil low pressure switch
28 Alternator (Option)
29 Alternator
30 Water in sail drive seal sensor (on sail drive)
31
Water in sail drive seal sensor
Amplifier (Sail drive only)
32 Battery (Option)
33 Battery
34 -
35 -
4
Alarm lamps
5 6 7 8
YW WL YG LB
10 diodes
Option
2
R
W
17 AC
30
R
G2 G1
L
1
L
WBr
B
3
P
O
Instrument panel (sub station) (Option)
Wire harness
Alarm lamps
14 15 16 17 18
YW WL YG LB
Fuse (3A) diodes
W
R
12
17 AC
30
R
11
G2 G1
L L
WBr
B
P
O
13
Instrument panel (Main station) (Option)
Wire harness
Wire harness for sub panel
9
Procured by customer
12V
32
12V
33
3R
Battery switch
2B
2R
22
2B
5R
3L
Relay
5R
21
Option
WBr 23
YW
27
B
W/Y
24
2R
3R
B
2W
S
25
28
Option
L
R
E
B
LB
RB
10B
LB
RB
10R
E
B
L
R
Y
29
O
YG B
Earth bolt
A
WL
26
A
B
L
YG
RB
31 only for sail drive
30 only for sail drive
3R 3W
3L
YW WL WG B
RB LB O YG
WB YR Y WR
YB GB G GR
Key switch
30 AC G1 G2 17
GLOW
OFF
ON
START
172
12. Electrical System
(2) For C-type instrument panel
(Color coding)
R
B
W
L
Red
Black
White
Blue
RB
LB
Red / Black
Blue / Black
YW Yellow / White
YB Yellow / Black
YG Yellow / Green
WL White / Blue
WB White / Black
WG White / Green
GR
O
Green / Red
Orange
WBr White / Brown
6
7
4
5
1
2
3
Starter switch
Stop switch
Tachometer / Hour meter
Buzzer
Lubricating oil low pressure alarm
Coolant high temperature alarm
Water in sail drive seal alarm
8
9
Battery low charge alarm
Relay (for 2 station : Option)
10 Fuse (3A)
11 Starter switch
12 Stop switch
13 Tachometer / Hour meter
14 Buzzer
15 Lubricating oil low pressure alarm
16 Coolant high temperature alarm
17 Water in sail drive seal alarm
18 Battery low charge alarm
19 Oil pressure meter
20 Coolant temperature meter
21 Air heater (Option)
22 Engine stop solenoid
23 Stop relay
24 Starter relay
25 Starter
26 Coolant high temperature switch
27 Lubricating oil low pressure switch
28 Alternator (Option)
29 Alternator
30 Water in sail drive seal sensor (on sail drive)
31
Water in sail drive seal sensor
Amplifier (Sail drive only)
32 Battery (Option)
33 Battery
34 Oil pressure sensor (Option)
35 Coolant temperature sensor (Option)
4
Alarm lamps
5 6 7 8
YW WL YG LB
10
Option
R
W
2
17 AC
30
R
1
G2
L
G1
L
WBr diodes
B
P
O
3
Instrument panel (sub station) (Option)
Wire harness
9
3R
Alarm lamps
14 15 16 17 18
YG G YG LB
Fuse (3A)
R
W
12
17 AC
30
R
11
G2
L
G1
L diodes
B
WBr
YW
19
YB WB
P
O
WL
20 13
Instrument panel (Main station) (Option)
Wire harness
Wire harness for sub panel
22
2B
2R
Procured by customer
12V
32
12V
33
Battery switch
2B
5R
3L
Relay
5R
21
Option
WL
WBr
23
YW
27
B
W/Y
24
3R
2R
B
2W
S
25
28
Option
L
R
E
B
LB
RB
10B
LB
RB
10R
E
B
L
R
Y
29
O
YG B
A
26
WB
YB
A
B
L
YG
RB
31 only for sail drive
34
35
3R 3W
3L
YW WL WG B
RB LB O YG
WB YR Y WR
YB GB G GR
30 only for sail drive
Key switch
30 AC G1 G2 17
GLOW
OFF
ON
START
Earth bolt
173
12. Electrical System
12.2 Battery
Refer to 2.2.3(2) for electrolyte level and battery charge.
Also refer to the service manual of the 3/4 JH3E series for other data regarding battery.
(1) Battery capacity
Since the battery has a minimum capacity of 12V, 80AH. it can be used for 80-120AH.
Battery capacity minimum standard cold district
Full charged specific gravity
12V-80AH
12V-100AH
12V-120AH
1.26
(2) Battery cable
Wiring must be performed with the specified electric wire. Thick, short wiring should be used to connect the battery to the starter, (soft automotive low-voltage wire [AV wire]) Using wire other than that specified may cause the fol. lowing troubles:
The overall length of the wire between the battery (+) terminal and the starter (B) terminal, and between the battery (-) terminal and the engine earth terminal, should be determined according to the following table.
Voltage system
12V
Allowable wiring voltage drop
0.2V or less/100A
Cross-section area Allowable length
< 0.86 (m)
15 (mm
2
)
20 (mm 2 )
30 (mm
2
)
40 (mm 2 )
50 (mm
2
)
60 (mm 2 )
< 1.3 (m)
< 2.3 (m)
< 2.8 (m)
< 3.5 (m)
< 4.1 (m)
Note :Excessive resistance in the key switch circuit (between the battery and start [S] terminals) can cause improper pinion engagement. To prevent this, follow the wiring diagram carefully.
174
12. Electrical System
12.3 Starting Motor
A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start.
12.3.1 Specifications
YANMAR Part No.
HITACHI Model No.
Nominal power (kW)
Nominal voltage (V)
Rating (sec)
Direction of Rotation
(Looking from the Pinion side)
Number of Pinion teeth
Weight (kg)
No load
Load
Terminal voltage (V)
Electric current (A)
Revolutions (min -1 )
Terminal voltage (V)
Electric current (A)
Torque (N•m)
Revolutions (min -1 )
129608-77010
S114-817A
1.4
12
30
Clockwise
11
3.0
11
90 (MAX)
2,700 (MIN)
8.4
250
8.3 (MIN)
1,000 (MIN)
12.3.2 Characteristics
2.4
48 6000 12
2.0
40 5000 10
1.6
32 4000 8
1.2
24 3000 6
0.8
16 2000 4
0.4
8 1000 2
0 0 0 0
0
Standard Performance 12V 1.4kW
V
200 kW min
400
-1
Current (A)
N m
600 800
175
12. Electrical System
12.3.3 Structure
(1) Disassembly drawing
Magnetic switch
Internal gear
Bracket
Pinion
Gear housing
Armature
Yoke
Rear cover
176
12. Electrical System
(2) Structure
When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion engages with the ring gear of a engine, and the engine is started.
Magnetic Switch Center Bracket (A)
Torsion Spring
Brush
Shift Lever
Gear Case
Pinion Shaft
Pinion
Rear Cover
Armature
Yoke
Planet Gear Center Bracket (P)
Internal Gear
12.3.4 Wiring diameter of a starting motor
1) When a starting switch is turned on, a magnet switch is charged, and a moving core is absorbed, and a pinion clutch is moved forward through a lever, and the pinion engages with a ring gear.
2) When the pinion engages the ring gear, because a main contact point is closed and the main electric current flows and a pull coil is shortcircuited by the main contact point and it stops being charged with electricity, the pinion is kept at the position by a holding coil during the start.
3) When the starting switch is turned off, the main contact point becomes open, and the pinion clutch is returned to the stop position by a return spring.
Starting switch
B
M
Battery
S
Magnetic switch
Mag
Mag
Starting motor
177
12. Electrical System
12.4 Alternator Standard, 12V/60A
The alternator serves to keep the battery constantly charged. It is installed on the cylinder block by a bracket, and is driven from the V-pulley at the end of the crankshaft by a V belt.
The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes.
12.4.1 Specifications
Yanmar code
Model of alternator
Model of IC regulator
Battery voltage
Nominal output
Earth polarity
Direction of rotation
(viewed from pulley end)
Weight
Rated speed
Operating speed
Speed for 13.5V at 20°C
Output current for 13.5V
Regulated voltage
128271-77200
LR160-741 (HITACHI)
SA-A (HITACHI)
12V
12V/60A
Negative earth
Clockwise
4.2 kg
5000 min -1
1,050-18,000 min -1
1050 min -1 or less
56A or more/ 5000 min -1
14.4
±0.3V (at 20°C, voltage gradient, -0.01V/°C)
178
12. Electrical System
12.4.2 Structure
(1) Disassembly drawing
Ball bearing
Fan
Pulley
Front bracket
Rotor
Stator
Rear bracket assembly
(12V60A alternator)
(2) Structure
Bracket
Nut
Pulley
Stator assembly
Rotor assembly
Rectifier assembly
Bracket
Packing
Ball bearing
Nut M5
Through bolt
Rotative direction
179
12. Electrical System
12.4.3 Wiring diagram
Condenser 2.2 F
Stator coil
Diode
Rotor coil
F
P
B S
1
L
BAT
P
IG
L
Key switch
Charge lamp
12V3.4W
Battery
E
IC regulator
E
Alternator
[NOTICE]
1) Don't do mis-connecting and short-circuit of each terminal.
2) Don't remove a battery terminal and a B terminal when rotating.
3) Shut out a battery switch during the alternator stop.
12.4.4 Standard output characteristics
The standard output characteristics of this alternator are shown as the below figure.
100
80
60
40
20
0
0 2
13.5V constant
4 6 8 10
Alternator speed (min -1 )
12
(Standard characteristics)
14 16 18 X 10 3
180
12. Electrical System
12.4.5 Inspection
(1) V belt inspection
1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually.
Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set.
2) V belt tension :
(Refer to 2.2.2.(4) in Chapter 2.)
(2) Visual check of wiring and check of unusual sound
1) Confirm whether wiring is right or there is no looseness of the terminal part.
2) Confirm that there is no unusual sound from the alternator during the engine operation.
(3) Inspection of charge lamp circuit
1) Move a start switch to the position of on. Confirm lighting of the charge lamp.
2) Start an engine, and confirm the lights-out of the lamp. Repair a charge lamp circuit when a lamp doesn't work.
Clearance
Normal Defect
(Inspection of V pulley)
181
12. Electrical System
12.5 Alternator 12V/80A (Optional)
12.5.1 Specifications
Yanmar code
Model of alternator
Model of IC regulator
Battery voltage
Nominal output
Earth polarity
Direction of rotation
(viewed from pulley end)
Weight
Rated speed
Operating speed
Speed for 13.5V at 20°C
Output current for 13.5V
Regulated voltage
119573-77201
LR180-03C (HITACHI)
TR1Z-63 (HITACHI)
12V
12V/80A
Negative earth
Clockwise
5.4 kg
5000 min
-1
1,200-9,000 min -1
1,200 min
-1 or less
75A or more/ 5000 min -1
14.5
±0.3V (at 20°C, voltage gradient, -0.01V/°C)
182
12. Electrical System
12.5.2 Structure
Disassembly drawing and Structure
Brush regulator assy
Stator
Fan
Front cover
Bearing retainer
Pulley
Spacer
Ball bearing
Rotor
Condenser
Diode
Rear cover
Capacitor assembly
Brush regulator assembly
Brush holder
Rear cover assembly
Diode assembly
Stator assembly
Front cover assembly
Bearing retainer
Ball bearing
Pulley nut assembly
Rotor assembly
Brush assembly
IC regulator assembly
Through bolt
Brush set
Ball bearing
Spacer
Pulley assembly
Rear cover
Insulating bushing
Screw (M5 x 0.8 X14)
183
12. Electrical System
12.5.3 Wiring diagram
Rotor coil
Stator coil
Diode
Sub-
Diode
R
Condenser
(3.2 F)
R
L 50
L
F
E
IC regulator
P
BAT
Key switch
Charge lamp
12V3.4W
E
Alternator
[NOTICE]
1) Don't do mis-connecting and short-circuit of each terminal.
2) Don't remove a battery terminal and a B terminal when rotating.
3) Shut out a battery switch during the alternator stop.
12.5.4 Standard output characteristics
The standard output characteristics of this alternator are shown as the below figure.
100
Battery switch
Battery
40
20
80
60
13.5V constant
0
0 2 4 6
Alternator speed (min -1 )
8
(Standard characteristics)
10 X 10
3
184
12. Electrical System
12.6 Instrument Panel
The new type instrument panels are applied for 3JH4E series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number.
The engine speed with new panel is activated by alternator B terminal pulse.
12.6.1 B-type instrument panel (optional)
Coolant high temperature alarm
Water in sail drive seal alarm
Lubricating oil low pressure alarm
Battery low charge alarm
STOP
10
0
20 30
40
50
B
GLOW
OFF
ON
START
Rubber seal,
B panel
Panel with cover foil
Tachometer Key switch
Hour meter
Stop button switch
Moisture cap for key switch
12.6.2 C-type instrument panel
Coolant high temperature alarm
Coolant
Sea water insufficient flow alarm temperature meter
Water in sail drive seal alarm
Water in fuel filter alarm
Battery low charge alarm
STOP
10
0
20 30
40
50
B
GLOW
OFF
ON
START
Rubber seal,
C panel
Panel with cover foil
Lubricating oil low pressure alarm
Tachometer
Lubricating oil pressure meter
Key switch
Hour meter
Stop button switch
Moisture cap for key switch
185
12.7 Warning Devices
12.7.1 Oil pressure alarm
If the engine oil pressure is below 0.01-0.03MPa (0.1-
0.3kgf/cm
2
, 1.42-4.26 lb/in.
2
), with the main switch in the ON position, the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp oil pressure switch ground circuit system. If the oil pressure is normal, the switch contacts are opened by the lubricating oil pressure and the lamp remains off.
Pilot lamp
Fuse
Main switch
Alarm buzzer
Oil pressure switch
Battery
OPTIONAL
Oil pressure sender
Damper
Oil pressure switch
Oil pressure
(Oil pressure alarm circuit)
Oil pressure
Contacts
12. Electrical System
Cylinder block
Spring
(Oil pressure switch)
Inspection
Problem
Lamp not illuminated when main switch set to ON
Lamp not extinguished while engine running
Inspection Item
1. Oil pressure lamp blown out
2. Operation of oil pressure switch
1. Oil level low
2. Oil pressure low
Inspection method
(1) Visual inspection
(2) Lamp not illuminated even when main switch set to ON position and terminals of oil pressure switch grounded
Lamp illuminated when checked as described in (2) above
Stop engine and check oil level with dipstick
Measure oil pressure
3. Oil pressure faulty
4. Wiring between lamp and oil pressure switch faulty
Switch faulty if abnormal at (1) and
(2) above
Cut the wiring between the lamp and switch and wire with separate wire
Corrective action
Replace the circuit of panel
Replace oil pressure switch
Add oil
Repair bearing wear and adjust regulator valve
Replace oil pressure switch
Repair wiring harness
186
12. Electrical System
12.7.2 Sender unit for lube oil pressure gauge
The sender unit for the lube oil pressure gauge has a mounting seat for mounting on the lube oil filter bracket.
Oil pressure is measured when the oil enters into the main gallery after being fed from the lube oil cooler and passing through the oil pressure control valve Be sure to mount a vibration damper when mounting the oil pressure sender unit.
OPTIONAL
Oil pressure sender
Damper
Oil pressure switch
Lube oil pressure sender unit
77
Cylinder block
Part code No.
Type
Rated voltage
Max. operating pressure
M4
119773-91650
Resistance switch
DC 12V
0.98MPa(10kgf/cm 2 )
ISO R1/8 Taper
187
12. Electrical System
12.7.3 Cooling water temperature alarm
A water temperature lamp and water temperature gauge, backed up by an alarm in the instrument panel, are used to monitor the temperature of the engine cooling water. A high thermal expansion material is set on the end of the water temperature unit. When the cooling water temperature reaches a specified high temperature, the contacts are closed, and an alarm lamp and buzzer are activated at the instrument panel.
Pilot lamp Fuse Main switch
Water temperature switch
Water temperature sender
Inlet for water heater
Fresh water pump
Alarm buzzer
Water temperature unit Battery
(Water temperature alarm circuit)
Operating temperature
Electric capacity
Response time
Indication color
Tightening torque
ON
OFF
97-103 deg.C
87 deg.C or high
DC 12V, 1A within 60sec.
Green
23.5-31.4N•m
(2.40-3.20kgf-m)
PT 3/8
12.7.4 Sender unit for the cooling water temperature gauge
The water temperature sender unit has a mounting seat for mounting on the fresh water pump unit. Water temperature is measured when the cooling water flows into the thermostat housing after leaving the cylinder head.
Part code No.
Type
Rated voltage
119773-91700
Thermistor switch
12V
M4
57.7mm
57.4
Green
ISO R3/8 Taper
188
12. Electrical System
12.8 Air Heater (Optional)
An air heater is available for warming intake air when starting in cold areas in winter. The air heater is mounted to the intake manifold. The device is operated by the glow switch on the instrument panel.
79
60
9
22
52 Air heater
Gasket
Relay
2-M6 x 1 terminal
4- 9
Intake manifold
Wire harness
Parts No.
Rated output
Rated current
Rated voltage
129120-77501
390W
35.5A
DC11V
189
12. Electrical System
12.9 Electric Engine Stopping
Device (Optional)
The electric engine stop device is fitted to the governor.
The device is operated by the stop switch on the instrument panel.
The emergency stop button is integrated with the solenoid. When pushing the stop button, the engine will shut down.
Emergency stop button
Stop solenoid
O-ring
Governor
190
13. SERVICE STANDARDS
13. SERVICE STANDARDS
13.1 Engine Tuning
No. Inspection item
1
2
3
4
5
6
Intake/exhaust valve clearance mm
V-belt tension at 98N (10kgf) mm
Between alternator and F.W. pump
Fuel injection pressure
Used part
New part
MPa (kgf/cm
2
)
Compression pressure (at 250 min -1 )
MPa (kgf/cm 2 )
Cooling water Capacity
(Liter)
Lube oil capacity (full)
Engine
Coolant recovery tank
3JH4E with KM35P
Liter
(rake angle 8 degree)
3JH4E with KM35A/
SD40
Liter
(rake angle 0 degree)
Marine gear KM35P
Liter
Marine gear KM35A
Liter
7
Lubricating oil pressure
MPa (kgf/cm 2 )
Standard
0.15-0.25
8-10
6-8
21.1-22.1
(215-225)
3.63±0.1
(37±1)
4.5
0.8
5.0±0.3
5.5±0.3
0.5
Limit
-
-
-
2.94±0.1
(30±1)
-
-
-
-
-
-
8
9
10
Oil pressure switch operating pressure
MPa (kgf/cm
2
)
Thermostat
Thermo switch actuating temperature
(deg.C)
11 Top clearance
ON
OFF
0.65
at rated speed at low idle speed
0.39-0.54
(4-5.5)
0.06(0.6) or above
0.02±0.01
(0.2±0.1) valve opening temperature deg. C
75.0-78.0
97-103
-
Full opening lift
(mm)
(temperature)
8 or above
(90 deg.C)
-
90 or more
0.68-0.80
-
-
Reference page
2.2.2(5)
2.2.2(4)
2.2.5(2)
3.4
2.2.1(5)
2.2.1.(3)
-
-
-
2.5
2.4.2
5.2.6
191
13. SERVICE STANDARDS
13.2 Engine Body
13.2.1 Cylinder head
(1) Cylinder head
Inspection item
Combustion surface distortion mm
Valve sink mm
Intake
Exhaust
Valve seat Seat angle Deg.
Intake
Exhaust
(2) Intake/exhaust valve and guide
Standard
0.05 or less
0.30-0.50
120
90
Intake
Inspection item
Guide inside diameter
Valve stem outside diameter
Clearance
Exhaust
Guide inside diameter
Valve stem outside diameter
Clearance
Valve guide projection from cylinder head
Valve guide driving-in method
(3) Valve spring
Inspection item
Free length
Inclination
(4) Rocker arm and shaft
Standard
44.4
-
Inspection item
Arm shaft hole diameter
Shaft outside diameter
Clearance
(5) Push rod
Inspection item
Bend
Standard
16.000-16.020
15.966-15.984
0.016-0.054
Standard
Less than 0.03
Standard
8.010-8.025
7.955-7.975
0.035-0.070
8.015-8.030
7.955-7.970
0.045-0.075
14.7-15.0
Cold-fitted
Limit
43.0
1.1
Limit
16.090
15.955
0.140
Limit
0.03
Limit
0.15
0.8
-
-
Reference page
5.2.1(1)
5.2.3(3)
5.2.1(3)
Limit
8.10
7.90
0.18
8.10
7.90
0.18
-
mm
Reference page
5.2.3
5.2.3(4)
Reference page mm
5.2.4(1)
Reference page mm
5.2.7(1)
Reference page
5.6.2(3) mm
192
13. SERVICE STANDARDS
13.2.2 Camshaft and gear train
(1) Camshaft
Side gap
Inspection item
Bending (1/2 the dial gage reading)
Standard
0.05-0.20
0.02 or less
38.600-38.800
Cam height
Shaft outside diameter / Metal inside diameter
Gear side
Bushing inside diameter 44.990-45.055
Camshaft outside diameter
44.925-44.950
Clearance 0.040-0.130
Bushing inside diameter 45.000-45.025
Intermediate
Flywheel side
Camshaft outside diameter
Clearance
44.910-44.935
0.065-0.115
Bushing inside diameter 45.000-45.025
Camshaft outside diameter
44.925-44.950
Clearance 0.050-0.100
(2) Idle gear shaft and bushing
Inspection item
Shaft outside diameter
Bushing inside diameter
Clearance
(3) Backlash of each gear
Inspection item
Crank gear, cam gear, idle gear, fuel injection pump gear and seawater pump gear
Standard
45.950-45.975
46.000-46.025
0.025-0.075
Standard
0.07-0.15
Limit
0.35
0.05
38.350
45.130
44.890
0.240
45.100
44.875
0.225
45.100
44.890
0.210
mm
Reference page
5.6.1(1)
5.6.1(4)
5.6.1(2)
5.6.1(3)
Limit
45.880
46.075
0.150
mm
Reference page
5.7.1(3)
Limit
0.17
mm
Reference page
5.7.1(1)
193
13. SERVICE STANDARDS
13.2.3 Cylinder block
(1) Cylinder block
Inspection item
Cylinder inside diameter
Roundness
Cylinder bore
Inclination
(2) Crankshaft
Standard
88.000-88.030
0.01 or less
Inspection item
Bending (1/2 the dial gauge reading)
Pin outside diameter
Crank pin
Standard
-
47.952-47.962
Metal inside diameter
Metal thickness
48.000-48.026
1.492-1.500
Clearance 0.038-0.074
Journal outside diameter 49.952-49.962
Crank journal
(Selective pairing)
Metal inside diameter
Metal thickness
Clearance
51.000-51.010
1.995-2.010
0.038-0.068
(3) Thrust bearing
Inspection item
Crankshaft side gap
(4) Piston and ring
1) Piston
Standard
0.14-0.22
Limit
0.30
Inspection item
Piston outside diameter
(Measure in the direction vertical to the piston pin.)
Piston diameter measure position
(Upward from the bottom end of the piston)
Hole inside diameter
Pin outside diameter
Clearance
Standard
87.950-87.960
22
26.000-26.009
25.995-26.000
0-0.014
Limit
88.200
0.03
mm
Reference page
5.1.5
Limit
0.02
47.902
-
-
0.150
49.902
-
-
0.150
mm
Reference page
5.5.1(2)
5.4.2(2)
5.5.1(3)
5.5.2(2)
Reference page
5.5.1(4) mm
Limit
87.900
-
26.020
25.900
0.074
mm
Reference page
5.3.1(1)
5.3.2
194
13. SERVICE STANDARDS
2) Piston ring
Inspection item
Top ring
Second ring
Oil ring
Ring groove width
Ring width
Side clearance
End clearance
Ring groove width
Ring width
Side clearance
End clearance
Ring groove width
Ring width
Side clearance
End clearance
(5) Connecting rod
Inspection item
Side clearance
Rod small end
Item
Bushing inside diameter
Pin outside diameter
Clearance
(6) Tappet
Inspection item
Tappet hole (block) inside diameter
Tappet stem outside diameter
Clearance
Standard
0.20-0.40
Standard
26.025-26.038
25.995-26.000
0.025-0.043
Standard
2.060-2.075
1.970-1.990
0.070-0.105
0.200-0.400
2.025-2.040
1.970-1.990
0.035-0.070
0.200-0.400
4.015-4.030
3.970-3.990
0.025-0.060
0.200-0.400
Limit
0.55
Limit
26.068
25.965
0.101
limit
2.170
1.950
0.200
0.490
2.140
1.950
0.190
0.490
4.130
3.950
0.180
0.490
mm
Reference page
5.3.3(1)
Reference page
5.4.1(2) mm
Reference page mm
5.3.2
5.4.3(1)
Standard
12.000-12.018
11.975-11.990
0.010-0.043
Limit
12.045
11.930
0.090
mm
Reference page
5.6.2(2)
195
13.3 Lubricating Oil System (Trochoid Pump)
(1) Outside clearance of outer rotor
Standard
0.12-0.21
Limit
0.30
mm
Reference page
8.2.4(1)
(2) Side clearance of outer rotor
Standard
0.02-0.07
Limit
0.12
(3) Inside clearance of inner rotor mm
Reference page
8.2.4(2)
13. SERVICE STANDARDS
Item
Inside clearance of inner rotor
Width across flat clearance of inner rotor
Parts Standard
Gear boss diameter 53.05-53.15
Rotor diameter 53.45-53.55
Width across flat of
Gear boss
Width across flat of rotor
49.45-49.75
49.95-50.05
Standard
0.3-0.5
0.2-0.6
Limit
0.6
0.7
mm
Reference page
8.2.4(3)
196
14. TIGHTENING TORQUE FOR BOLTS AND NUTS
14. TIGHTENING TORQUE FOR BOLTS AND NUTS
14.1 Main Bolt and Nut
No Name
1 Head bolt
2 Rod bolt
3 Flywheel retainer bolt
4 Metal cap retainer bolt
5
Crankshaft pulley bolt
(FC300 pulley)
6 Fuel pump gear nut
7 Nozzle fastening bolt
8
Fuel injection pipe joint nut
9
Starter relay terminal nut
Thread diameter x pitch (mm)
M10 x 1.25
M9 x 1.0
M10 x 1.25
M12 x 1.5
M14 x 1.5
M14 x 1.5
M8 x 1.25
M12 x 1.5
M6 x 1
Lubricating oil application
(thread portion, and seat surface)
Coat with lube oil
Coat with lube oil
Coat with lube oil
Coat with lube oil
Coat with lube oil
Coat with lube oil
No lube oil
No lube oil
No lube oil
Torque
N•m(kgf-m)
85.2-91.2 (8.69-9.30 )
44.1-49.1 (4.50-5.01)
83.3-88.3 (8.49-9.00)
96-100 (9.79-10.2)
83.2-93.2 (8.48-9.50)
78-88 (8-9)
24.4-28.4 (2.49-2.90)
29.4-34.4 (3.00-3.51)
3.0-4.2 (0.31-0.43)
14.2 Standard Bolts and Nuts (without lube oil)
Name
Hexagon bolt t (7T) and nut
Screw dia. x pitch (mm)
M6 x 1
M8 x 1.25
M10 x 1.5
M12 x 1.75
Tightening torque
9.8-11.8 (1.0-1.2)
22.5-28.5 (2.3-2.9)
44-54 (4.5-5.5)
78.2-98.2 (8.0-10.0)
N•m (kgf-m)
Remarks
Use 80% of the value at left when the tightening part is aluminum.
Use 60% of the value at left for 4T bolts and lock nuts.
PT plug
Pipe joint bolt
1/8
1/4
3/8
1/2
M8
M10
M12
M14
M16
9.8 (1.0)
19.6 (2.0)
29.4 (3.0)
58.8 (6.0)
12.7-16.7 (1.3-1.7)
19.5-25.5 (2.0-2.6)
24.4-34.4 (2.5-3.5)
39.1-49.1 (4.0-5.0)
48.9-58.9 (5.0-6.0)
197
YANMAR MARINE INTERNATIONAL B.V.
P.O. BOX 30112,1303 AC ALMERE NL
BRUGPLEIN 11, 1332 BS ALMERE-DE VAART, THE NETHERLANDS
TEL : 31-36-5493211
FAX : 31-36-5493549
YANMAR DIESEL AMERICA CORP.
101 INTERNATIONAL DRIVE
ADAIRSVILLE, GA 30103, U.S.A.
TEL : 1-770-877-6229
FAX : 1-770-877-9009
YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD.
4 TUAS LANE, SINGAPORE 638613
TEL : 65-6861-3855
FAX : 65-6862-5195
YANMAR CO,. LTD.
MARINE FACTORY
ENGINE PRODUCT OPERATIONS DIVISION
5-3-1, TSUKAGUCHI HONMACHI, AMAGASAKI-SHI, HYOGO 661,JAPAN
TEL : 81-6-6428-3123
FAX : 81-6-6421-5549
Printed in Japan
January, 2004
Advertisement
Key features
- Compact and lightweight design
- Highly fuel-efficient
- Advanced technology
- Durable construction
- California Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
